Ford 2002 E-550 Super Duty Cutaway Supplementary Manual

2002

MARCH 2002

REFERENCE INFORMATION

FORD TRUCK BODY BUILDER ADVISORY SERVICE

The Ford Truck Body Builder Advisory Service assistance may be
consulted regarding information contained in this manual. For assistance:

 Call [phone]
 Fax [phone]
 E-Mail [e-mail]

or at the BBAS website ­www.fleet.ford.com/truckbbas

Include your name, company and telephone number with all inquiries. If
requesting written materials, include your mailing address.

The specifications and designs
described herein are believed to be
correct as of the time that this book
was approved for printing, but accuracy
cannot be guaranteed. They are
intended only to provide basic data
regarding such matters as dimensions
and weight ratings of Ford-built
chassis. The information contained in
this book is general and nothing
contained herein is to be regarded as
providing specific or comprehensive
instructions for the completion of a
particular vehicle or as authorization by
Ford of the specific modifications,
alteration or designs of individual
vehicles.

Representations regarding the
compliance of any Ford-manufactured
incomplete vehicle to any rule,
regulation or standard issued pursuant
to the National Traffic and Motor
Vehicle Safety Act or the Canadian
Motor Vehicle Safety Act are set forth
only in the incomplete vehicle manual
which accompanies each incomplete
vehicle. Ford reserves the right to
discontinue models or change
specifications or designs at any time
without notice and without incurring
any obligation.

Regulations such as those issued by the
Federal Highway Administration (FHWA)
or issued pursuant to the Occupational
Safety and Health Act (OSHA), and/or
state, provincial, and local laws and
regulations may require installation of
additional equipment for the particular
use intended for the vehicle. It is the
responsibility of the subsequent stage
manufacturer or completed vehicle alterer
and the vehicle purchaser to ascertain
how the vehicle will ultimately be used, if
FHA, OSHA or state provincial or local
regulations apply and how the vehicle as
completed will comply with those
requirements.

Nothing contained herein is to be
construed as a representation that such
equipment required for the particular use
intended has been installed on the
incomplete vehicle.

IMPORT ANT NOTICE

INDEX/FEATURES

Index 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Metric/U.S. Unit Equivalents 2. . . . . . . . . . . . . . . . . . . .

Model Lineup 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Reference SgRP X & Z Locations 4. . . . . . . . . . .

Safety Section

Seat Restraint System 5-7. . . . . . . . . . . . . . . . . . . . . . .

Air Bag Supplemental Restraint System 8–9. . . . . . . .

E-550 Super Duty Cutaway

159.5 - 233.5 Wheelbase (DRW) 10. . . . . . . . . . . .

Vehicle Height/T ire/Ground Clearance Data 11. . . . . .

All Wheelbases 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensional Frame Data

159.5 WB Frame & Body Pucks 13. . . . . . . . . . . . . .

177.5 - 191.5 WB Frame Data 14. . . . . . . . . . . . . .

209.5 - 233.5 WB Frame Data 15. . . . . . . . . . . . . .

55 Gallon Aft of Axle Fuel Tank 16. . . . . . . . . . . . . . . . .

Fuel Filler Systems 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensional Body Data 18. . . . . . . . . . . . . . . . . . . . . . . .

Body Section A 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Wiring 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEATURES

CHASSIS

 5 wheelbase lengths 159.5, 177.5, 191.5, 209.5 and 233.5
 New suspensions with GVWR availability: 17,500 pounds and 19,000 pounds

(front and rear suspension)

 ABS brakes
 New steering (40 wheel cut)

EXTERIOR

 Cutaway cab
 Front fender flares
 Running boards
 Freshened grille & hood
 Roof marker lights (optional)
 New front bumper

POWERTRAINS

Standard Optional

 Engine 6.8L Gas 7.3L Diesel
 Transmission 4R100 4R100
 Horsepower 305@4250 215@2600
 Torque (ft-lbs) 420@3250 425@1800
 Rear axle ratio 4.88 4.88 LS/5.38, 5.38 LS

NOTE: For Design Recommendations and Second Unit Body Information refer to the 2002 Body
Builders Layout Book.

METRIC/U.S. CUSTOMARY UNIT EQUIVALENTS

BB0689

TYPICAL LONGITUDINAL

PLANE

GROUND

HORIZONTAL

PLANE (mm)

PLANE

VERTICAL
TRANSVERSE

PLANE

MM THREE–DIMENSIONAL REFERENCE SYSTEM

X

Y

Z

Z

“0 ”

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Page 2 E-550 SUPER DUTY CUTAWAY

Multiply: by: to get: Multiply: by: to get: Multiply: by: to get: Multiply: by: to get:
LINEAR FUEL ECONOMY

inches X 25.4 = millimetres(mm) X 0.03937 = inches miles/gal X 0.4251 = kilometres/litre (km/l) X 2.352 = miles/gal
inches X 2.54 = centimetres (cm) X 0.3937 = inches gal/mile X 2.3524 = litres/kilometre (l/km) X 0.42517 = gal/mile
feet X 0.3048 = metres (m) X 3.281 = feet gal/mile X 235.24 = litres/100 kilometre (l/km) X 0.004252 = gal/mile

AREA POWER

inches

2

X 645.16 = millimetres

2

(mm2) X 0.00155 = inches

2

horsepower X 0.746 = kilowatts (kW) X 1.34 = horsepower

inches

2

X 6.452 = centimetres2 (cm2) X 0.155 = inches

2

ft-lb/min X 0.0226 = watts(W) X 44.27 = ft-lbf/min

feet

2

X 0.0929 = metres2 (m2) X 10.764 = feet

2

TORQUE

VOLUME

lb-in X 0.11298 = newton-metres (N-m) X 8.851 = lb-in

inches

3

X 16387.0 = millimetres3 (mm3) X 0.000061 = inches

3

lb-feet X 1.3558 = newton-metres (N-m) X 0.7376 = lb-feet

inches

3

X 16.387 = centimetres3 (cm3) X 0.06102 = inches

3

inches

3

X 0.01639 = litres (1) X 61.024 = inches

3

VELOCITY

quarts X 0.94635 = litres (1) X 1.0567 = quarts miles/hr X 1.6093 = kilometres/hr (km/hr) X 0.6214 = miles/hr
gallons X 3.7854 = litres (1) X 0.2642 = gallons kilometres/hr X 0.27778 = metres/sec (m/s) X 3.600 = kilometres/hr
feet

3

X 28.317 = litres (1) X 0.03531 = feet

3

miles/hr X 0.4470 = metres/sec (m/s) X 2.237 = miles/hr

feet

3

X 0.02832 = metres3 (m3) X 35.315 = feet

3

fluid oz. X 29.57 = millilitres (ml) X 0.03382 = fluid oz.

COMMON METRIC PREFIXES

mega (M) = 1,000,000 centi (c) = 0.01

MASS

kilo (k) = 1,000 milli (m) = 0.001
ounces (av) X 28.35 = grams (g) X 0.03527 = ounces (av) hecto (h) = 100 micro (µ) = 0.000001
lb (av) X 0.4536 = kilograms (kg) X 2.2046 = lb (av)
tons (2000 lb) X 907.18 = kilograms (kg) X 0.001102 = tons (2000 lb)
tons (2000 lb) X 0.9078 = tonne (t) X 1.1025 = tons (2000 lb)

“ ”

NOTE  [ ] DIMENSIONS ARE INCHES.

E-550 SUPER DUTY CUTAWAY

MODEL LINEUP

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Page 3 E-550 SUPER DUTY CUTAWAY

*

BASE CURB WEIGHT*

MODEL

SERIES

CODE

WHEELBASE

mm/inches

GVWR

pounds

STANDARD

TRANSMISSION

ENGINES

liters

FRONT
pounds

REAR

pounds

TOTAL

pounds

4051.3

6.8 3405 2785 6190

4051.3

[159.5]

17,500/19,000

4R100

7.3 3787 2857 6644

4508.5

6.8 3475 2844 6319

4508.5

[177.5]

17,500/19,000

4R100

7.3 3857 2910 6767

E-550
p

4864.1

6.8 3537 2894 6431

S

uper Duty
Cutaway

E55

4864.1

[191.5]

17,500/19,000

4R100

7.3 3921 2958 6879

y

5321.3

6.8 3617 2959 6576

5321.3

[209.5]

17,500/19,000

4R100

7.3 4003 3019 7022

5930.9

6.8 3722 3046 6768

5930.9

[233.5]

17,500/19,000

4R100

7.3 4112 3102 7214

* Weight calculated with fuel and fluids to full capacity.

THIS INFORMATION IS PROVIDED TO ASSIST IN THE
INSTALLATION OF SEATS OTHER THAN FORD INSTALLED
SEATS AND TO HELP PRESERVE THE INTENDED
PERFORMANCE OF THE SAFETY AND ERGONOMIC
FEATURES OF THE 2002 E-SERIES. THE MID-TRACK
H-POINT LOCATION MUST BE MAINTAINED IN ORDER TO
COMPLY WITH FMVSS 208 AIRBAG REQUIREMENTS.

NOTES  [ ] DIMENSIONS ARE INCHES.

nnn

N

NOTES —

E-550 SUPER DUTY CUTAWAY

SEAT TRACK TRAVEL/H-POINT LOCATION

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Page 4 E-550 SUPER DUTY CUTAWAY

FOREMOST
H POINT

REARMOST
H POINT

MID–TRACK
H POINT

FRONT FIDUCIAL
MARK

SgRP

FOREMOST
H POINT

REARMOST
H POINT

MID–TRACK
H POINT

FRONT FIDUCIAL
MARK

SgRP

DRIVER

MANUAL TRACK

FRONT PASSENGER

MANUAL TRACK

FOREMOST
H POINT

REARMOST
H POINT

MID–TRACK
H POINT

SgRP

FRONT PASSENGER MANUAL TRACK

FIXED SEAT BACK

FRONT FIDUCIAL
MARK

FRONT FIDUCIAL
MARK

SgRP

MID–TRACK
H POINT

DRIVER

POWER TRACK

BB0056

175
[6.9]

155

[6.1]

150
[5.9]

28

[1.1]

84

[3.3]

51

[2.0]

41

[1.6]

13

[0.5]

10

[0.4]

25

[0.1]

33

[1.3]

10

[0.4]

18

[0.7]

208
[8.2]

388 REF

[15.3]

657 REF

[25.9]

24

[0.9]

89

[3.5]

10

[0.4]

1.4

[0.05]

168

[6.6]

178

[7.0]

388 REF

[15.3]

657 REF

[25.9]

24

[0.9]

89

[3.5]

10

[0.4]

1.4

[0.05]

168
[6.6]

178
[7.0]

447 REF

[17.6]

650 REF

[25.6]

18

[0.7]

59

[2.3]

10

[0.4]

1.4

[0.05]

129
[5.1]

139
[5.5]

653 REF

[25.8]

427 REF

[16.8]

E-550 SUPER DUTY CUTAWAY

OCCUPANT PROTECTION SYSTEMS

SEAT RESTRAINT SYSTEM

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Page 5 E-550 SUPER DUTY CUTAWAY

INFORMATION

The following recommendations are intended to
assist in the design of seats and seat belt systems
capable of meeting the requirements of the F/CMVSS
207, 208, 209 and 210 except for front seating
positions for vehicles having a GVWR of 3855 kg
[8500 lb] or less, and an Unloaded Vehicle Weight of
2495 kg [5500 lb] or less.These recommendations
are based on testing and analyses performed by Ford
Motor Company.

Ford cautions subsequent stage manufacturers to
note the definition of “Designated Seating Positions”
on page 26 of the “2001 Body Builder Book”. If a
position can reasonably be used by a 5th percentile
adult female for seating and the overall seat
configuration and vehicle design make it likely that the
position will be used by an occupant while the vehicle
is in motion, then the position must be considered to
be a “Designated Seating Position” for determination
of compliance to U.S. and Canadian motor vehicle
safety standards.

Seat and seat belt systems may take many forms; this
list of recommendations cannot cover all possibilities.
Strict adherence to these suggestions will not ensure
that systems will comply with F/CMVSS 207, 208, 209
and 210. Responsibility for determining compliance to
appropriate F/CMVSS regulations is that of the final
stage manufacturer. Accordingly, Ford Motor
Company makes no representation as to the
appropriateness of any particular recommendation in
its specific application of a particular design or act of
intermediate or final stage manufacture.

To confidently verify compliance with F/CMVSS 207,
208, 209 and 210, the testing of representative
systems to applicable F/CMVSS 207, 208, 209 and
210 procedures is recommended. Questions
regarding compliance with F/CMVSS regulations
should be directed to your legal counsel, the National
Highway Traffic Safety Administration, or Transport
Canada.

SEAT SYSTEMS

1. For Incomplete E-Series Vans and Cutaways with
a GVWR over 3855 kg (8500 lb) purchased with
the front seat delete option, Ford strongly
recommends following the practices specified in
the compliance representations for F/CMVSS 208
that apply to Incomplete E-Series Vans with a
GVWR of 3855 kg (8500 lb) or less and
completed units Unloaded Vehicle Weight of 2495
kg (5500 lb) or less that are purchased without
front seats.

2 Any additional seats and seat anchorages

installed by subsequent stage manufacturers
must meet F/CMVSS 207 requirements and
specifications.

3. Do not modify or alter Ford furnished seating or
occupant restraint system. When utilizing the
Ford seat delete package, care must be taken to
insure proper function of the seat adjustment
latching mechanism, electrical wiring and seat
belt buckle pretensioner. Refer to Bulletin Q-48 for
wire routing.

4. If the seat or seat belt components are temporarily
removed for any reason, they must be reinstalled
in accordance with the instructions and
specifications found on the following pages for
E-Series or the applicable

Ford Truck Shop

Manual.

5. Seating systems that include the attachment of
lap belt or shoulder belt assemblies should also
consider the requirements of F/CMVSS 210 as
part of the seating system.

6. Seating system components should be free of
sharp edges to prevent damage to seat belt
systems when the belts could potentially contact
the seating system components.

7. Seats should be mounted with appropriate
fasteners in the mounting holes provided, since
these holes are located to utilize floor pan
structural reinforcements. (See figures on
following pages.)

8. If additional holes are required for any reason,
their locations should be carefully selected so that
the structural integrity of the floor pan will not be
compromised and to prevent damage to other
components located below the floor.

9. Seating systems should be designed to be
compatible with the seat belt systems, so as to
permit proper adjustment, allow for occupant
movement and provide convenient accessibility of
the restraint system buckle release.

10. Seats not designated for occupancy while the
vehicle is in motion must be conspicuously
labeled as such.

LAP AND SHOULDER BELT SYSTEMS

1. The front seats are equipped with a pyrotechnic
buckle pretensioner. The buckle pretensioner
reduces slack in the lap and shoulder safety belt
by pulling the buckle downward. The buckle
pretensioners and air bags operate on the same
sensors and will function simultaneously.

2. Additional lap and shoulder belt assemblies,
including retractors and hardware, must comply
with the requirements of F/CMVSS 208 and 209.

3. Additional lap and shoulder belt system
anchorages must comply with the requirements of
F/CMVSS 210.

4. Lap and shoulder belt systems that are attached
to seat frame or base may affect compliance of
the seating system with the requirements of
F/CMVSS 207.

5. Ford lap and shoulder belts, retractors and
attaching hardware should not be altered or
modified in any way. The reinstallation of these
components should follow the instructions and
specifications on the following pages, or those in
the appropriate

Ford Truck Shop Manual

.

6. Lap and shoulder belt assemblies should be
compatible with the seat systems and
anchorages so that lap belts will be properly
positioned about the occupant’s pelvis to provide
proper adjustment and fit. The buckle and buckle
release are properly located with respect to the
occupant and must comply with the requirements
of F/CMVSS 208.

7. Seat belt warning system activation/deactivation,
where applicable, should be provided by the lap
and shoulder belt assembly.

WARNING:

THE SEAT BELT BUCKLE PRETENSIONER,
AIRBAGS AND ELECTRONIC SENSOR MODULE
ARE BAR CODED WITH A UNIQUE SERIAL
NUMBER WHICH IS MATCHED TO THE VEHICLE
VIN. TO MAINTAIN THE OCCUPANT PROTECTION
SYSTEM PERFORMANCE, THE COMPLETED
VEHICLE MUST CONTAIN THE SAME SEAT BELT
BUCKLE PRETENSIONER, AIR BAGS AND
ELECTRONIC SENSOR MODULE THAT WERE
INSTALLED BY FORD MOTOR COMPANY.
FAILURE TO DO SO COULD RESULT IN SERIOUS
INJURY IN THE EVENT OF A COLLISION.

OCCUPANT PROTECTION ZONE A ND OVERHEAD
CONSOLE

For vehicles completed with an Unloaded Vehicle
Weight (UVW) greater than 2495 kg [5500 lb], Ford
strongly recommends following the practices in the
compliance representations for F/CMVSS 208 regarding
overhead console specifications that apply to
Incomplete E-Series Vans with a GVWR of 3856 kg
[8500 lb] or less and completed units have an Unloaded
Vehicle Weight of 2495 kg [5500 lb] or less. (Refer to
the

Incomplete Vehicle Manual

for these compliance

representations.)