Ford 5C2S-19A268-AA User Manual

DO NOT DESTROY: THIS MANUAL IS REQUIRED BY LAW. KEEP UNTIL THE VEHICLE IS COMPLETED BY THE FINAL STAGE MANUFACTURER.

2005

E-SERIES

INCOMPLETE VEHICLE MANUAL

Incomplete Vehicle Types

For This Manual

INCOMPLETE E-SERIES VANS &

WAGONS

E-SERIES CUTAWAY

E-SERIES BASIC CHASSIS

May, 2004

5C2S-19A268-AA

U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS

(APPLICATION BY VEHICLE TYPE)

Bus (Not Truck Truck Standard School School (Not (Walk-in (1)

Number Title of Standard Bus) Bus Walk-In Van) MPV Van) Equip.

101 Control Location, Identication and Illumination X X X X X 102 Transmission Shift Lever Sequence, Starter

Interlock & Transmission Braking Effect X X X X X 103 Windshield Defrosting & Defogging Systems X X X X X 104 Windshield Wiping and Washing Systems X X X X X 105 Hydraulic and Electric Brake Systems X X X X X 106 Brake Hoses X X X X X X 108 Lamps, Reective Devices & Associated Equipment X X X X X X

108.1 Headlamps (Canada only) X X X X X X 110 Tire Selection and Rims (U.S. only) X X X X X X 111 Rearview Mirrors X X X X X 113 Hood Latch Systems X X X X X 114 Theft Protection X(2) X(2) 115 Vehicle Identication Number (Canada only) X X X X X 116 Hydraulic Brake Fluids X X X X X X 118 Power Operated Window, Partition, and Roof

Panel Systems X(2) X(2) X(2) 119 New Pneumatic Tires for Vehicles Other

Than Passenger Cars X 120 Tire Selection and Rims for Motor Vehicles

Other Than Passenger Cars X X X X X X 124 Accelerator Control Systems X X X X X 131 School Bus Pedestrian Safety Devices (except

Multifunction School Activity Bus) X 135 Light Vehicle Brake Systems X(10) X(10) X(10) X(10) X(10) 201 Occupant Protection in Interior Impact X(2)(9) X(2)(9) X(2) X(2) X(2)(9) 202 Head Restraints X(2) X(2) X(2) X(2) X(2) 203 Impact Protection for the Driver from the

Steering Control System X(2) X(2) X(2) X(2) 204 Steering Control Rearward Displacement X(3) X(3) X(3) X(3) 205 Glazing Materials X X X X X X 206 Door Locks and Door Retention Components X X X 207 Seating System X X X X X 208 Occupant Crash Protection X(5)(6) X(5)(6) X(5)(6) X(5)(6) X(5)(6) X 209 Seat Belt Assemblies X X X X 210 Seat Belt Assembly Anchorages X X X X X

210.1 User-Ready Tether Anchorages for Restraint Systems (Canada only) X X X X

210.2 Lower Universal Anchorage Systems for Restraint Systems and Booster Cushions (Canada only) X X X X

212 Windshield Mounting X(2) X(2) X(2) X(2) 213 Child Restraint Systems X X X X X X 214 Side Impact Protection X(2)(7) X(2) X(2)(7) X(2)(7) 217 Bus Window Retention and Release X X 219 Windshield Zone Intrusion X(2) X(2) X(2) X(2)

(Continued on Page 1)

E-SERIES (May, 2004)

U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS

(APPLICATION BY VEHICLE TYPE)

(Continued from Inside Front Cover)

Bus (Not Truck Truck Standard School School (Not (Walk-in (1)

Number Title of Standard Bus) Bus Walk-In Van) MPV Van) Equip.

220 School Bus Rollover Protection X 221 School Bus Body Joint Strength X 222 School Bus Passenger Seating and Crash

Protection X 225 Child Restraint Anchorage Systems (U.S. only) X(8) X(8) X(8) X(8) X(8) 301 Fuel System Integrity X(2) X X(2) X(2) X(2) 302 Flammability of Interior Materials X X X X X PART Vehicle Identication Number (U.S. only) X X X X X

565.4 1106 Noise Emissions (Canada only) X X X X X

(1) Applicable to Equipment for use on applicable vehicle types.

(2) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb]

or less.

(3) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb]

or less and an unloaded vehicle weight of 2495 kg [5500 lb] or less.

(4) Applicable to vehicles with a GVWR of 2722 kg [6000 lb] or

less.

(5) Injury criteria required for vehicles with a GVWR of 3856 kg

[8500 lb] or less and an unloaded vehicle weight of 2495 kg [5500 lb] or less except, in U.S., walk-in van-type trucks and vehicles designed to be sold exclusively to the U.S. Postal Service and, in Canada, vehicles manufactured for operation by persons with disabilities.

(6) Injury criteria is optional for some vehicles where not required.

(7) Dynamic Performance Requirements apply to MPV, truck or a

bus with a GVWR of 2722 kg [6000 lb] or less.

(8) Tether anchors and latch/ISO Fix lower anchors that are installed

voluntarily or by regulation must comply with this Standard.

(9) The requirements of section S6 of Standard Number 201 (United

States) do not apply to buses with a GVWR more than 3860 kg [8510 lb] and walk-in van type trucks.

(10) Applicable to vehicles with a GVWR of 3500 kg [7716 lb] or

less.

E-SERIES (May, 2004) 1

E-SERIES (May, 2004) 3

INTRODUCTION

Information in this manual is furnished pursuant to United States and Canadian safety regulations or, in some cases where the information is not required by regulation, is furnished for the convenience of intermediate or nal stage vehicle manufacturers. Incomplete vehicles manufactured for sale or importation into the U.S., are specially equipped for the United States. The descriptions and statements contained in the manual relate only to motor vehicle safety standards issued under the National Trafc and Motor Vehicle Safety Act of 1966 as amended.

An incomplete vehicle manufactured for sale or importation into Canada is specially equipped for Canada. This vehicle conforms to the applicable Canadian Motor Vehicle Safety Standards (CMVSS) on the date of manufacture printed on the cover of this manual. Requirements unique to vehicles for use in Canada are identied in the Statements of Conformity and the “Canadian Vehicles”, page 48.

The Emission Certication Information section of this manual contains information regarding conformity to exhaust emission regulations of the United States, Canada, and the State of California and fuel economy regulations of the United States.

This manual should not be relied upon with respect to compliance with any regulation of the Federal Highway Administration or regulations issued pursuant to the Occupational Safety and Health Act (OSHA) or any other federal, state, or local regulations governing the performance or construction of motor vehicles (except for those requirements shown under the headings “Unleaded Gasoline Label,” page 49, “Warranty and Maintenance,” page 50, and “Emission Control Information Label,” page 50). It is the responsibility of the nal stage manufacturer to determine applicability and comply with any federal, state, or local requirements not detailed in this manual.

IMPORTANT:

UNITED STATES VEHICLES

Ford Motor Company has endeavored, whenever possible, to state the specific conditions under which an incomplete vehicle may be completed to conform to each applicable Federal Motor Vehicle Safety Standard. These specic statements are intended to aid subsequent stage manufacturers in avoiding instances of inadvertent noncompliance to particular standards.

Note that the nal responsibility for the compliance of the completed vehicle rests with the nal stage manufacturer who is required by law to certify, as prescribed by Section

567.5 of Title 49, Code of Federal Regulations, that the completed vehicle conforms to all applicable Federal Motor Vehicle Safety Standards and that all applicable federal, state and California emission/noise standards are conformed with.

Ford Motor Company does not make any representation as to the appropriateness of modications for any particular application other than expressly stated herein. Intermediate and nal stage manufacturers must exercise proper engineering judgment to determine if a modication is appropriate for their specic application.

IMPORTANT:

UNITED STATES AND CANADIAN VEHICLES

Alterations to an incomplete vehicle by someone other than Ford Motor Company, or damage in transit, may affect compliance statements that are furnished in this manual, or representations that are printed on the label that may be afxed to a vehicle.

INTRODUCTION

E-SERIES (May, 2004)2

TABLE OF CONTENTS

DEFINITIONS .................................................................................... 4-5

GENERAL INFORMATION .................................................................... 6

Directions........................................................................................... 6

VEHICLE DESCRIPTION ..................................................................... 7

COMPLETED VEHICLE TYPES .............................................................8

STATEMENTS OF CONFORMITY................................................... 9-47

CANADIAN VEHICLES

Vehicle Identication ........................................................................ 48

Daytime Running Lamp (DRL)......................................................... 48

Canadian Radio Frequency Interference (RFI)................................ 48

EMISSION CERTIFICATION INFORMATION

Medium Duty Passenger Vehicles (MDPV).......................................49

Frontal Area and Weight Restrictions ...............................................49

High Altitude Requirements..............................................................49

Emission Control Hardware ..............................................................49

Unleaded Gasoline Label ................................................................ 49

Exterior Noise .................................................................................. 50

Tampering with Noise Controls .........................................................50

Warranty and Maintenance.............................................................. 50

Evaporative Emissions..................................................................... 50

Malfunction Indicator Light (MIL) ..................................................... 50

Ozone Depleting Substance (ODS)..................................................50

Emission Control Information Label................................................. 50

California Fuel Vapor Recovery ....................................................... 51

California Motor Vehicle Emission Control Label ............................. 51

Radio Frequency Interference (RFI) ................................................ 51

SUPPLEMENTS .................................................................................. 52

REFERENCE INFORMATION ............................................. Back Cover

E-SERIES (May, 2004) 3

TABLE OF CONTENTS

DEFINITIONS

The following denitions are from Title 49, Code of Federal Regulations, Parts 567.3, 568.3 and 571.3 where noted. Canadian denitions are from Canada Motor Vehicle Safety Regulations, Section 2(1), and are in italics. Ford Motor Company denitions are for the purpose of this manual only. Some terms are followed by an abbreviation that is used throughout this manual.

Ambulance – is a vehicle for emergency medical care which

provides: A driver’s compartment; a patient compartment to accommodate an Emergency Medical Technician (EMT), Paramedic, and two litter patients (one patient on the primary cot and secondary patient on folding litter located on the squad bench) so positioned that the primary patient can be given intensive life-support during transit; equipment and supplies for emergency care at the scene as well as during transport; two-way radio communication; and, when necessary, equipment for light rescue/extrication procedures. The Ambulance shall be designed and constructed to afford safety, comfort, and avoid aggravation of the patient’s injury or illness. (From Federal Specication KKK-A-1822-E). Ford Motor Company also includes within its denition of ambulance any vehicle that is used for transporting life-support equipment, for rescue operations, or for nonemergency patient transfer if the engine of the vehicle is equipped with a “throttle kicker” device, which enables an operator to increase engine speed over normal idle speed when the vehicle is not moving.

B-Pillar – is the vehicle body structure located directly

rearward of each front door. This structure will include the outer panel, all inner panels or reinforcements which support the door opening, the door latching system, and/or the roof structure. (Ford Motor Company)

Basic (Stripped) Chassis – an incomplete vehicle, without

occupant compartment, that requires the addition of an occu pant compartment and cargo-carrying, work performing, or load-bearing components to perform its intended function. (Ford Motor Company)

Bu s – a motor veh icle with motive po wer, exce pt a

trailer, designed for carr ying more than 10 persons. (49CFR571.3)

Bus (Canada) – a vehicle having a designated seating capacity

of more than 10, but does not include a trailer or a vehicle imported temporarily for special purposes. (autobus)

Chassis Cab – an incomplete vehicle, with completed occupant

compartment, that requires only the addition of cargocarrying, work performing, or load-bearing components to perform its intended functions. (49CFR567.3)

Completed Vehicle – a vehicle that requires no further

manufacturing operations to perform its intended function, other than the addition of readily attachable components, such as mirrors or tire and rim assemblies, or minor nishing operations such as painting. (49CFR568.3)

Critical Control Item – is a component or procedure which

may affect compliance with a federal regulation or, which could directly affect the safe operation of the vehicle. The identifying symbol is an inverted delta ( ). (Ford Motor Company)

Cutaway Chassis – an incomplete vehicle that has the back

of the cab cut out for the intended installation of a structure that permits access from the driver’s area to the back of the completed vehicle. (Ford Motor Company)

Cutaway Chassis (Canada) – an incomplete vehicle that has

the back of the cab cut out for the intended installation of a structure that permits access from the driver’s area to the back of the vehicle. (châssis tronqué)

Designated Seating Position – any plan view location

capable of accommodating a person at least as large as a 5th percentile adult female, if the overall seat conguration and design and vehicle design is such that the position is likely to be used as a seating position while the vehicle is in motion, except for auxiliary seating accommodations such as temporary or folding jump seats. Any bench or split-bench seat in passenger car, truck, or multipurpose passenger vehicle with a GVWR less than 4,536 kilograms (10,000 pounds), or having greater than 50 inches of hip room (measured in accordance with SAE Standard J1100(a)) shall have not less than three designated seating positions, unless the seat design or vehicle design is such that the center position cannot be used for seating. (49CFR571.3) (abbreviated by Ford Motor Company)

Designated Seating Position (Canada) – any plan view

position capable of accommodating a person at least as large as a 5th percentile adult female, as dened in section 100 of Schedule IV, where the overall seat conguration and design and the vehicle design are such that the position is likely to be used as a seating position while the vehicle is in motion, but does not include any plan view position of temporary or folding jump seats or other auxiliary seating accommodation. (place assise désignée)

Final-Stage Manufacturer – a person who performs such

manufacturing operations on an incomplete vehicle that it becomes a completed vehicle. (49CFR568.3)

Gross Axle Weight Rating (GAWR) – the value specied

by the vehicle manufacturer as the load-carrying capacity of a single axle system, as measured at the tire-ground interfaces. (49CFR571.3)

Gross Combination Weight Rating (GCWR) – the value

specied by the manufacturer as the loaded weight of a combination vehicle. (49CFR571.3)

Gross Vehicle Weight Rating (GVWR) – the value specied

by the manufacturer as the loaded weight of a single vehicle. (49CFR571.3)

H-Point – the mechanically hinged hip point of a manikin

which simulates the actual pivot center of the human torso and thigh, described in SAE Recommended Practice J826, “Manikins For Use in Defining Vehicle Seating Accommodations,” November 1962. (49CFR571.3)

H-point (Canada) – the mechanically hinged hip point of a

manikin that simulates the actual pivot centre of the human torso and thigh, described in SAE Standard J826 APR80, Devices for Use in Dening and Measuring Vehicle Seating Accommodation. (point H)

Incomplete Vehicle – an assemblage consisting, as a

minimum, of frame and chassis structure, power train, steering system, suspension system, and braking system, to the extent that those systems are to be part of the completed vehicle, that requires further manufacturing operations, other than the addition of readily attachable components such as mirrors or tire and rim assemblies, or minor nishing operations, such as painting, to become a completed vehicle. (49CFR568.3)

DEFINITIONS

E-SERIES (May, 2004)4 E-SERIES (May, 2004) 5

Incomplete Vehicle (Canada) – a vehicle (a) other than a

vehicle imported temporarily for special purposes, that is capable of being driven and that consists, at a minimum, of a chassis structure, power train, steering system, suspension system and braking system in the state in which those systems are to be par t of the completed vehicle, but requires further manufacturing operations to become a completed vehicle or (b) that is an incomplete trailer. (véhicule incomplet)

In com plete Veh icle Manu fac tur er – a pe rso n wh o

manufactures a n incomplet e vehi cle by a ssembling components none of which, taken separately, constitute an incomplete vehicle. (49CFR568.3)

Intermediate Manufacturer – a person, other than the

in compl ete veh icle man ufactur er or the final st age manufacturer, who performs manufacturing operations on an incomplete vehicle. (49CFR568.3)

Motor Home – a multi-purpose vehicle with motive power that is

designed to provide temporary residential accommodations, as evidenced by the presence of at least four of the following facilities: Cooking; refrigeration or ice box; selfcontained toilet; heating and/or air conditioning; a potable water supply system including a faucet and a sink; and a separate 110-125 volt electrical power supply and/or an LP gas supply. (49CFR571.3)

Multifunction School Activity Bus (MFSAB) – a school bus

whose purposes do not include transporting students to and from home or school bus stops. (49CFR571.3)

Multipurpose Passenger Vehicle (MPV) – a motor vehicle

with motive power, except a low-speed vehicle or trailer, designed to carry 10 persons or less which is constructed either on a truck chassis or with special features for occasional off-road operation. (49CFR571.3)

Multipurpose Passenger Vehicle (MPV) (Canada) – a vehicle

having a designated seating capacity of 10 or less that is constructed either on a truck-chassis or with special features for occasional off-road operation, but does not include an air cushion vehicle, an all-terrain vehicle, a golf cart, a lowspeed vehicle, a passenger car, a truck or a vehicle imported temporarily for special purposes. (véhicule de tourisme à usages multiples)

School Bus – a bus that is sold, or introduced in interstate

commerce, for purposes that include carrying students to and from school or related events, but does not include a bus designed and sold for operation as a common carrier in urban transportation. (49CFR571.3)

School Bus (Canada) – a bus designed or equipped primarily

to carry students to and from school. (autobus scolaire)

Seating Reference Point – the unique design H-point, as

dened in SAE J1100 (June 1984), which (abbreviated by Ford Motor Company):

(a) Establishes the rearmost normal design driving or

riding position of each designated seating position in a vehicle;

(b) Has X, Y, and Z coordinates established relative to the

designed vehicle structure;

torso and thigh; and

(d) Is the reference point employed to position the two-

dimensional drafting template described in SAE J826 (May 1987).

Seating Reference Point (Canada) – the unique Design H-

point, as dened in section 2.2.11.1 of SAE Recommended Practice J1100 (June 1993), that

(a) establishes the rearmost normal design driving or riding

position of each designated seating position, taking into account all modes of adjustment – horizontal, vertical and tilt – in a vehicle,

(b) has X, Y and Z coordinates, as defined in section

2.2.3 of SAE Recommended Practice J1100 (June

1993), established relative to the designed vehicle structure,

torso and thigh, and

(d) is the reference point employed to position the H-point

template with the 95th percentile leg, as described in section 3.1 of SAE Standard J826 (June 1992), or, if that drafting template cannot be positioned, the reference point when the seat is in its rearmost adjustment position. (point de référence de position assise)

Second Unit Body (SUB) – consists of the body structure

and/or all the cargo carrying, work performing, and/or load bearing components and/or equipment installed by a subsequent stage manufacturer on an incomplete vehicle, such that the incomplete vehicle becomes a completed vehicle. (Ford Motor Company)

Subsequent Stage Manufacturer – a term which means

either intermediate or nal stage manufacturers or both. (Ford Motor Company)

Trimmed Seat – a complete functional seat assembly including

the seat pedestal, seat track, seat base frame, seat back, recliner mechanism, seat padding, all attaching hardware, and the nal trim material (i.e., cloth, leather, or vinyl). (Ford Motor Company)

Truck – a motor vehicle with motive power, except a trailer,

designed primarily for the transportation of property or special purpose equipment. (49CFR571.3)

Truck (Canada) – a vehicle designed pr imarily for the

transportation of property or special-purpose equipment but does not include a competition vehicle, a crawlermounted vehicle, a trailer, a work vehicle, a vehicle imported temporarily for special purposes or a vehicle designed for operation exclusively off-road. (camion)

Unloaded Vehicle Weight (UVW) – the weight of a vehicle

with maximum capacity of all uids necessary for operation of the vehicle, but without cargo, occupants, or accessories that are ordinarily removed from the vehicle when it is not in use. (49CFR571.3)

Unloaded Vehicle Weight (Canada) – the weight of a vehicle

equipped with the containers for the uids necessary for the operation of the vehicle lled to their maximum capacity, but without cargo or occupants. (poids du véhicule sans charge)

Untrimmed Seat – the structure including the seat pedestal,

seat track, seat base frame, seat back, recliner mechanism, seat padding, and all attaching hardware required for a functional seat assembly without the nal trim material (e.g., cloth, leather, or vinyl) and trim material attaching components. (Ford Motor Company)

Walk-In Van – a step entry city delivery van type vehicle that

permits a person to enter the vehicle without stooping. This denition by Ford Motor Company is based on information appearing in 41 FR 54945, published December 16,1976, and in 42 FR 34288, published July 5,1977.

Walk-In Van (Canada) – a van type of truck in which a person

having a height of 1700 mm can enter the occupant compartment in an upright position by a front door. (fourgon à accès en position debout)

E-SERIES (May, 2004) 5

DEFINITIONS

E-SERIES (May, 2004) 7

GENERAL INFORMATION

Information in this section is provided pursuant to Part 568 of Title 49, Code of Federal Regulations. “Vehicles Manufactured in Two or More Stages.” Part 568 species that nal stage manufacturers must complete vehicles in compliance with all applicable Federal Motor Vehicle Safety Standards, and Section 6 of the Canadian Motor Vehicle Safety Regulations (CMVSR), Vehicles Manufactured in Stages. Section 6.6 of the CMVSR provides labeling requirements for vehicles that are to be sold in Canada.

DIRECTIONS

STATEMENTS OF CONFORMITY

The Statements of Conformity section, which begin on page 9 of this manual, lists the Federal Motor Vehicle Safety Standards in effect on the date of manufacture of this incomplete vehicle that are applicable to the type(s) of completed vehicles into which this incomplete vehicle may be manufactured. This date is shown on the label afxed to the cover of this manual. These statements, in most cases, apply to specic types of incomplete or completed vehicles and identify GVWR and UVW weight ranges.

The incomplete vehicle type is identied by the 5th, 6th, and 7th digits of the Vehicle Identification Number (VIN); see page 7. The completed vehicle types to which this incomplete vehicle may appropriately be completed is printed on the label, under the heading “May Be Completed As,” that is afxed to the cover of this document. The Completed Vehicle Types charts on page 8 identies how various incomplete vehicles with an Optional Prep Packages or a Trim Code, may be completed.

Each statement of conformity is identied by a safety standard number located at the left margin. Because there may be multiple statements of conformity for each safety standard, use care to select the appropriate statement. Unique CMVSS requirements will be identified at the conclusion of the representations for a particular safety standard.

Compliance statements provided in this manual are of the three following types:

Type I • A statement that the vehicle, when completed,

will conform to the standard if no alterations are made in identied components of the incomplete vehicle.

Type II • A sta tem ent of specific conditio ns of fi nal

manufacture under which the incomplete vehicle manufacturer species that the completed vehicle will conform to the standard.

Type III • A statement of conformity with the standard is

not substantially affected by the design of the incomplete vehicle, and that the incomplete vehicle manufacturer makes no representation as to conformity with the standard.

IMPORTANT:

To rely on the compliance representations in this manual, the incomplete vehicles must be completed as one of the completed vehicle types designated on the label afxed to the cover of this manual, and must not exceed the specied GVWR, GAWRs, or the Unloaded Vehicle Weight limits when specied in this manual.

VEHICLE SPECIAL ORDER (VSO) VEHICLES

VSO vehicles can be identied by a six digit number with the letters VSO below the digits in the lower right corner of the Incomplete Vehicle Label which is afxed to the driver-door lock pillar. See the sample label on page 7.

The Statements of Conformity section of this manual includes compliance representations for certain VSO vehicles. These vehicles are identied in the charts on page 8. Other VSO vehicles may require additional Statements of Conformity which will be in the Supplement Section of this manual.

FORD TRUCK ASSISTANCE

Throughout this manual you will nd references to information found in the Ford Truck Body Builders Layout Book. Additional Design Recommendations and specications are also provided to assist subsequent stage manufacturers in completing incomplete vehicles. To obtain a free copy of this publication on CD-ROM or to receive an order form for additional CD-ROM’s or books please visit our website at www.eet.ford.com/truckbbas. Under Publications select Body Builders Order Forms. All dealer requests can be handled online. All other U.S. orders should be faxed to (734) 713-2971. Canadian orders should be faxed to (905) 670-0844.

The Ford Truck Body Builder Advisory Ser vice may be consulted regarding information contained in this manual.

• Call (877) 840-4338

• Fax (313) 594-2633

• E-Mai l bbasqa@ ford .com or a t the BBA S website – www.eet.ford.com/truckbbas

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

GENERAL INFORMATION

E-SERIES (May, 2004)6

VEHICLE DESCRIPTION

The cover of this manual identifies the three incomplete

vehicle con gurations for which compliance representations

for the speci c vehicle to which this manual belongs. The label

vehicle with the corresponding VIN.

The GVWR

The front and rear GAWRs

Tire and wheel size

vehicle may be manufactured

All E-Series incomplete vehicles manufactured by Ford Motor

The 5th, 6th, and 7th digits of the Vehicle Identification

three digits are used in the Completed Vehicle Types charts

the VIN on the incomplete vehicle label, when provided, will

The Canadian Motor Vehicle Safety Act and Regulations

with the National Safety mark on it on vehicles manufactured

for sale in Canada. A label representative of those installed by

vehicle type charts on page 8 will identify incomplete vehicles

wish to rely on the Statements of Conformity or, in some cases,

vehicle and the label on the front of this manual will identify

the prep package.

INCOMPLETE VEHICLE MANUFACTURED BY

FORD MOTOR COMPANY

MADE IN U.S.A.

GVWR:

FRONT GAWR

VIN

PSI COLD

WITH TIRES RIMS

REAR GAWR

EXTERIOR PAINT COLORS

TYPEGVW

BODY

TRANS

AXLE

TAPE

SPRINGS

161

F379

AJ8

E 6

N Y

4200LB 1905KG LT215/85R16D 16X6K

11000LB/4989KG

8250LB 3742KG LT215/85R16D 16X6K

DUAL

F85B1520472AB

TYPICAL E-SERIES - U.S.

TYPICAL E-SERIES - CANADA

VSO

410047

BAR CODE V.I.N (CALIFORNIA

)

VSO VEHICLE

DATE OF MANUFACTURE

VEHICLE TYPE (SEE CHART ON PAGE 8)

OPTIONAL PREP PACKAGE

VSO VEHICLE

DATE OF MANUFACTURE

VEHICLE TYPE (SEE CHART ON PAGE 8)

01/05

DATE

01/05

DATE

1FDKE37HZ5HA24638

EQUIPPED WITH THE FORD AMBULANCE PREP PKG.

VSO

1019

1FDKE37HZ5HA24639

E-SERIES (May, 2004) 9

COMPLETED VEHICLE TYPES

COMPLETED VEHICLES

5TH, 6TH, 7TH

VIN DIGIT

E-Series

E11 Incomplete E-150 Wagon X 6 E14 Incomplete E-150 Regular Van X 5 E24 Incomplete E-250 Regular Van X 5 E31 Incomplete E-350 Super Duty Wagon X 6 6 E34 Incomplete E-350 Super Duty Regular Van X 5 1 E35 E-350 Super Duty Cutaway X 3 1 4 2 E39 E-350 Super Duty Basic (Stripped) Chassis X E45 E-450 Super Duty Cutaway X 3 1 4 2 E49 E-450 Super Duty Basic (Stripped) Chassis X S24 Incomplete E-250 Extended Van X 5 S31 Incomplete E-350 Super Duty Extended Wagon X 6 6 S34 Incomplete E-350 Super Duty Extended Van X 5 1 5

IMPORTANT: Ford Motor Company makes no representation that the completed vehicle types listed above are the only vehicle types appropriate for the incomplete vehicles listed. However, if a unit is completed as a vehicle type other than as listed above, the Statements of Conformity may not be applicable.

INCOMPLETE VEHICLES

(1) Ambulance Prep Package

(2) School Bus Prep Package

- E-350 available on 9600 lb GVWR Single Rear Wheels (SRW), and 11,500 lb GVWR Dual Rear Wheels (DRW) only

(3) Motorhome Prep Package

(4) Shuttle Bus Prep Package

(5) Recreational Van

(6) Center Aisle Seat Prep Package

TRUCK

(WALK-IN VAN)

MPV

(AMBULANCE)

BUS (NOT

SCHOOL BUS)

SCHOOL BUS

COMPLETED VEHICLE TYPES

E-SERIES (May, 2004)8

STATEMENTS OF CONFORMITY

The following Statements of Conformity apply to vehicles that are produced for sale or importation into the United States or Canada. The term “Incomplete Vehicle Types” in these statements refers to the three types of the vehicles illustrated on this manual’s cover and listed in the chart on page 8.

The number preceding each Statement of Conformity refers to the number designation for a Part or a Section of Part 571 of the Federal Motor Vehicle Safety Standard.

The statements provided for each safety standard number are appropriate compliance representations for each Canadian safety standard number if this incomplete vehicle, identied by the VIN on the front of the document, was manufactured by Ford Motor Company for sale or use in Canada, except as may be noted at the conclusion of each safety standard number.

PART

565.4 The statement below is applicable to all incomplete vehicle types except the Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Part 565.4, Vehicle Identication Number, if the vehicle identication number mounted on the top of the instrument panel is not removed, altered, or modied and no actions are taken by the subsequent stage manufacturer that would obstruct the readability of the Vehicle Identification Number mounted on the top of the instrument panel.

565.4 The statements below are applicable to the following incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

This vehicle, when completed, will conform to Part

565.4, Vehicle Identication Number, if:

• The E-Series vehicle identication number printed on the label afxed to the cover of this manual is mounted and displayed in accordance with the requirements of this Standard.

101 The statements below are applicable to the following

incomplete vehicle types when equipped with a driver seat:

• Incomplete E-Series Van or Wagon

• Cutaway

This vehicle, when completed, will conform to Standard 101, Controls and Displays if:

• The controls, displays, and their identifications supplied by Ford Motor Company are not removed, relocated, altered, or modied.

• The components, wiring, and power supply installed by Ford Motor Company to illuminate any control, display, or their identification are not removed or altered so as to affect lighting performance.

• Components added to the vehicle do not obstruct the driver’s ability to operate or visually locate the controls, displays, and their identications.

• The driver-seat is not replaced, relocated, or modied other than for the addition of seat trim.

Any controls, displays, and illumination added to this vehicle must conform to the requirements of this Standard.

101 The statements below are applicable to the following

incomplete vehicle types with no driver-seat:

• Incomplete E-Series Van

• Cutaway

This vehicle, when completed will conform to Standard 101, Controls and Displays if:

• The Seating Reference Point (see denition on page

5) and the seat back torso angle of the driver-seat when completed or installed by a subsequent stage manufacturer are located as shown in the Figure C page 32, for E-Series type vehicles.

• The c on tr ol s, displays, and their identifications supplied by Ford Motor Company are not removed, altered, or relocated.

• The components, wiring, or power supply installed by Ford Motor Company to illuminate any control, display, or their identication are not removed or altered so as to affect lighting performance.

• Components added to the vehicle do not obstruct the driver’s ability to operate or visually locate the controls, displays, and their identications.

Any controls, d is pl ays, an d illumination added to this vehicle must conform to the requirements of this Standard.

101 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 101, Controls and Displays, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

E-SERIES (May, 2004) 9

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 11

102 The statements below are applicable to all incomplete

100

BRAKE

SERVIC

I N

INSTRUMENT CLUSTER

CABLE

STEERING COLUMN

CABLE

THUMB WHEEL

COLUMN SHIF

LEVER

FRONT OF VEHICLE

CABLE RETENTION BRACKET

SHIFT LEVER RETAINER PI

N800705 SCRE

TORQUE 20-29 IN.LB

[ ] ALL DIMENSIONS ARE INCHES

3.0-3.5 LB. WEIGHT

HAND TOOL

[2.375] ± 0.25 DIA.

(PRNDL)

HOLE: [1.125] DIA.

X [2.188] 0.25 DEEP

(PRNDL) ADJUSTMENT TOLERANCE

RIGHT LIMITLEFT LIMIT TARGET

vehicle types except the Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Standard 102, Transmission Shift Leve r Sequence, Starter Inte rlock, and Transm ission Braki ng Effect, if no alterations or adjustments are made to the transmission, shift cable, transmission outer shift lever, shift cable bracket, vacuum tubes, vacuum pump system, brakeshift interlock system, starter interlock system, wiring circuit from the interlock switch to the power source, and transmission gear selector indicator (PRNDL).

If an auxiliary transmission is added to this vehicle, it must conform to the requirements of this Standard.

INSTALLATION OF GEAR SELECTOR INDICATOR (PRNDL) FOR E-SERIES BASIC (STRIPPED) CHASSIS

102 The statements below are applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

This vehicle, when completed, will conform to Standard 102, Transmission Shift Leve r Sequence, Starter Interlock, and Transmission Braking Effect if:

• No alterations or ad ju stments are made to the transmission, shift cable, transmission outer shift lever, shift cable bracket, vacuum tubes, vacuum pump system, brake-shift interlock system, the starter interlock system, and wiring circuit from the interlock switch to the power source.

• The E-Series Basic (Stripped) Chassis is equipped with a temporary transmission gear selector indicator (PRNDL) which must be replaced with the cluster and transmission gear selector indicator (PRNDL) that is shipped with the vehicle in the dunnage box and must be installed and adjusted following the instructions and specications shown in the gure below.

If an auxiliary transmission is added to this vehicle, it must conform to the requirements of this Standard.

1. Route the cable after the instrument cluster is installed in the vehicle. Do not kink the cable. Do not bend the cable to a radius less than 4.5 inches. Route the cable from the cluster in a counter-clockwise direction, under the steering column, using the screw provided. Do not wrap the cable around the steering column. The steering column shroud installation should not affect the cable routing or function.

2. Pull on the cable end loop for a functional check. The cable should operate with a similar effort as required prior to routing. Then place the cable loop on the shift lever retainer pin.

3. Rotate the column shift lever clockwise until it bottoms out in rst gear.

4. Rotate the column shift lever counter-clockwise 3 detents for Overdrive “Oval D” position for TorqShift™ transmissions.

5. Install a 3 pound weight, as dened in this illustration, on the end of the column shift lever.

6. Center the pointer in the middle of the “Oval D” position by rotating the thumb wheel.

7. Remove the 3 pound weight. The pointer must be within the tolerances as dened in this illustration.

8. After the steering column shrouds are installed, the transmission gear selector indicator (PRNDL) system must be checked for proper operation.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)10

103 The statement below is applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis:

This vehicle, when completed, will conform to Standard 103, Windshield Defrosting and Defogging Systems, if no alterations or adjustments are made to heater and blower assemblies, ducting, operating controls, electrical circuit from the blower assembly to the power source, windshield, coolant hoses from the radiator or engine to the heater, and if no obstructions are added that restrict or otherwise redirect the air flow from the defroster outlets to the windshield.

103 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 103, Windshield Defrosting and Defogging Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

104 The statement below is applicable to all incomplete

vehicle types except the Basic (Stripped) Chassis:

This vehicle when completed, will conform to Standard 104, Windshield Wiping and Washing Systems, if no alterations are made to the windshield, the windshield wiping and washing system, including the electrical circuit from the windshield wiping and washing motors to the power source, and if no obstructions are added that restrict or otherwise redirect uid ow from the washer nozzles to the windshield.

104 The statement below is applicable to the following

incomplete vehicle type:

• E-Series Basic (Stripped) Chassis

Conformity with Standard 104. Windshield Wiping and Washing Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.

105 INFORMATION

Incomplete vehicle weight and dimensional information required for center of gravity calculations are available in the Ford Source Book. See your local Ford Dealer and refer to appropriate model year and specic vehicle for required information.

Abbreviation denitions and a vehicle diagram to assist with the equations for the Standard 105 segment are shown on page 14.

NOTE: 105 is an example of a standard with conformity statements that contain minimum requirements for completed vehicle Unloaded Vehicle Weight (UVW, see definition on page 5). Maximum UVW requirements are also found in various sections of this manual (see especially Standards 212/219 and 301 and related table, Table A). Completed vehicles must meet UVW limits imposed by all applicable requirements.

105 The statements below are applicable to the E-Series

cutaway when equipped with the School Bus Prep package and completed as a school bus:

This vehicle when completed, will conform to Standard 105, Hydraulic and Electric Brake Systems, if:

• No alterations, modications, or replacements are made to the following:

– Service or parking brake system – Antilock brake system – Vacuum system – Wheels and tires – Brake system indicator lamp and wiring – Brake system reservoir labeling – Suspension ride height or spring rate – Hydro-Boost system – Power Steering pump and lines if used with

Hydro-boost – Engine belt drive system – Wheelbase

• The E-350 SRW Unloaded Vehicle Weight (see denition on page 5) is not less than the minimum value of 2540 kg [5600 lb].

• The E-350/450 DRW minimum UVW must be at least the weights shown on the following table:

MINIMUM UNLOADED VEHICLE WEIGHT (UVW)

Vehicle Weight Kilogram [Pound]

E-350 DRW 3673 [8100] E-450 DRW 4128 [9100]

• The maximum GAWRs and GVWR, as identied on the cover of this document, are not exceeded.

• The transverse center of gravity is less than 50.8 mm [2.0 in] either side of the vehicle centerline for E-350 only.

• Service or parking brake pedal assembly operation must not be restricted by any alteration or added components.

• The horizontal and vertical center of gravity, of the completed vehicle at Unloaded Vehicle Weight, is within the minimum and maximum locations as dened in the following table:

CENTER OF GRAVITY FOR E-SERIES CUTAWAY

COMPLETED AS A SCHOOL BUS

E-350 E-350 E-450

Location SRW DRW DRW mm [in] mm [in] mm [in]

Vertical Maximum (1) 302.0 [11.9]

Horizontal Maximum (2) 2159.0 2718.0 [85.0] [107.0]

Horizontal Minimum (2) 1651.0 [65.0]

E-SERIES (May, 2004) 11

(1) Measured from top of frame at a point midway between

the centerlines of the front and rear axles.

(2) Measured rearward from the centerline of the front axle.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 13

105 The statements below are applicable to the following

incomplete vehicle types if the GVWR is between 3500 kg [7716 lb] and 3629 kg [8000 lb]:

• Incomplete E-Series Van or Wagon

This vehicle, when completed, will conform to Standard 105, Hydraulic and Electric Brake Systems, if:

• No alterations, modications, or replacements are made to the following:

• Any removal of a Ford body or chassis component is accompanied by the addition of equal weight.

• The maximum GAWRs and GVWR, as identied on the cover of this document, are not exceeded with the vehicle weight at Unloaded Vehicle Weight + 400 lb passenger load.

• The ser v ice or pa rking bra ke pedal assembly operation is not restricted by any alteration or added components.

• The horizontal center of gravity of the Second Unit Body (SUB) is rearward of L vehicle description in the chart below. Lmin does not apply to a SUB of 120 lb or less when installed rearward of the front seats and forward of the centerline of the rear axle. (Do not restrict the E-Series seat travel and provide seatback clearance to obtain the torso angle as shown in Figure C page 32).

• The horizontal center of gravity for the SUB is:

† for the appropriate

min

– At or forward of the r ear axle center line. The

vertical center of gravity for the completed vehicle at Unloaded Vehicle Weight + 400 lb passenger load CGv (Equation A) must not exceed 36.0 inches, when measured from the ground.

– Behind the rear axle centerline. The vertical center

of gravity for the completed vehicle at Unloaded Vehicle Weight + 400 lb passenger load must fall within the appropriate range determined from Table E, page 16. The value of CGh (Equation B), which approximates the horizontal center of gravity of the completed vehicle, is used in Table E, to determine the vertical center of gravity limits for the completed vehicle. The value CGv (Equation A), which approximates the vertical center of gravity of the completed vehicle, must fall within the appropriate range determined from Table E.

EQUATION A

CGvbWb + CGvc Wc + 25P

CGv =

EQUATION B

Wrb + Wrc +

105 (Continued Next Page)

(

P x CG

(

)

x WB

HORIZONTAL CENTER OF GRAVITY

FORWARD LIMIT

Wheelbase L Vehicle Millimeter [inch] Millimeter [inch]

E-250 3505 [138] 1524 [60]

min

† L

= the minimum horizontal center of gravity of the

min

SUB measured in inches rearward from the centerline of the front axle.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)12

105 (Continued)

105 The statements below are applicable to the following

incomplete vehicle types except when completed as a school bus, and if the GVWR is between 3629 kg [8000 lb] and 6373 kg [14,050 lb] inclusive:

• Incomplete E-Series Van or Wagon

• E-Series Cutaway

• E-Series Basic (Stripped) Chassis

This vehicle, when completed, will conform to Standard 105, Hydraulic and Electric Brake Systems, if:

• No alterations, modications, or replacements are made to the following:

– Service or parking brake system – Antilock brake system – Vacuum system – Wheels and tires – Brake system indicator lamp and wiring – Brake system reservoir labeling – Suspension ride height or spring rate – Hydro-boost system – Power steering pump and lines if used with Hydro-

boost – Engine belt drive system – Wheelbase

• No additional sound deadene r or r ust proofing material, that may be applied to the vehicle, can interfere with proper parking brake cable function.

• No par t of add on equipment, i.e. toolboxes, flat bed attaching brackets, etc., can interfere with the movement of parking brake cables or air ow to rear brake assembly.

• Any removal of a Ford body or chassis component is accompanied by the addition of equal weight.

• E-Series Cutaway and Basic (Stripped) Chassis vehicles conform to the minimum SUB weights found in Table B, page 15.

• The maximum GAWRs and GVWR, as identied on the cover of this document, are not exceeded with the vehicle weight at Unloaded Vehicle Weight + Passenger Load (P). (See E-Series Passenger Load chart on this page.)

• The ser v ice or pa rking bra ke pedal assembly operation is not restricted by any alteration or added components.

• The SUB horizontal center of gravity must be at or forward of the rear axle centerline for the following vehicles:

- E-350/450 Basic (Stripped) Chassis

- E-350 Super Duty Cutaway (DRW)

- E-450 Super Duty Cutaway

The horizontal center of gravity for the SUB is:

– At or forward of the rear axle centerline. The vertical

center of gravity for the completed vehicle at GVWR CGv (Equation C) must not exceed 48.0 inches when measured from the ground.

– Behind the rear axle centerline. The vertical center

of gravity for the completed vehicle at GVWR must fall within the appropriate range determined from Table E page 16. The value of CGh (Equation D), which approximates the horizontal center of gravity of the completed vehicle, is used in Table E to determine the vertical center of gravity limits for the completed vehicle. The value of CGv (Equation C) which approximates the vertical center of gravity of the completed vehicle must fall within the appropriate range determined from Table E.

EQUATION C

CGvbWb + CG

CGv =

Wc + W

(

GVWR

)

+ 25P

EQUATION D

CGh =

Wrb + Wrc +

(

P x CG

(

)

+ W

)

x WB

GVWR

E-SERIES PASSENGER LOAD

GVWR [lb] P [lb] 0 - 7716 397

7717 - 10,000 400 10,001 - 19,000 500

E-SERIES (May, 2004) 13

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004) 15

FMVSS 105 & 135 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE E-SERIES VEHICLES

CG OF SUB

CG OF COMPLETED VEHICLE

CG OF CHASSIS

GVWR

SUB

L† = Horizontal distance in inches between the SUB

center of gravity and the of the front axle.

P = Passenger load (See E-Series Passenger Load

Table page 13).

CGv = Vertical distance from the ground to the center of

gravity [inches] of the completed vehicle.

CGh = Horizontal distance from of the front wheels to

completed vehicle center of gravity [inches].

CGvb = Vertical distance from the ground to the center of

gravity of the SUB and/or permanently attached added equipment [inches].

CGvc = Vertical distance from the ground to the center

of gravity of the chassis [inches] (including cab if original equipment). (Taken from Table F, page 16).

CGhp = Horizontal distance from the of the front

wheels to the P [inches] (passenger load) (taken from Table D, page 16).

Wb = Weight of the SUB and/or permanently attached

added equipment [pounds].

Wrb = Weight at t he rear whe els o f the S UB

and/or permanently attached added equipment [pounds].

Wrc = Weight at the rear wheels of the vehicle (chassis

and cab) (fuel tanks full) [pounds]. Including option weight.

† Required for <8000 lb. GVWR calculations only. ‡ Required for ≥8000 lb. GVWR calculations only.

Wc = Weight of the vehicle (chassis and cab) (fuel

tanks full) [pounds]. Including option weight.

WB = Vehicle wheelbase [inches].

Wt = Total unladen weight = (Wb + Wc + P)

GVWR = Gross Vehicle Weight Rating of the vehicle

[pounds].

WI‡ = Remaining cargo capacity [pounds].

Where: Wl = GVWR - (Wb + Wc + P)

Wrl‡ = Weight of the remaining cargo capacity on the

rear wheels [pounds].

CGhI‡ = Horizontal distance from the

WrI =

(CGhI)W

of the front wheels to the cargo center of gravity [inches] (taken from Table C page 16). For many common vehicles, the CGhI is not given in the table, then it may be estimated as the distance from the of the front wheel to the horizontal midpoint of the cargo area.

SUB = A Second Unit Bo dy consis ts of the bod y

structure and/or all the cargo carrying, work performing, and/or load bearing components and/or equipment installed by a subsequent stage manufacturer on an incomplete vehicle, such that the incomplete vehicle becomes a completed vehicle.

STATEMENTS OF CONFORMITY

E-SERIES (May, 2004)14

TABLE A

Maximum Unloaded Vehicle Weight (UVW) for Incomplete Vehicles When Completed (2)

(This Information Does Not Apply To Vehicles Over 4536 kg [10,000 lb] GVWR)

Wheelbase

Millimeter Maximum Model [inch] Unloaded Vehicle Weights – Kilogram [pound]

E-150 Regular Van 3505 [138] 2699 [5950](1) E-150 Regular Wagon 3505 [138] 2699 [5950](1) E-250 Regular and Extended Van 3505 [138] 3130 [6900] E-350 Regular and Extended Van 3505 [138] 3583 [7900] E-350 Regular and Extended Wagon 3505 [138] 3583 [7900] E-350 Cutaway 3505 [138] 3856 [8500] E-350 Basic (Stripped) Chassis SRW 3505 [138] 3946 [8700] E-350 Basic (Stripped) Chassis DRW 3505 [138] 3946 [8700] E-350 Basic (Stripped) Chassis SRW 4013 [158] 3946 [8700] E-350 Basic (Stripped) Chassis DRW 4013 [158] 3946 [8700] E-350 Basic (Stripped) Chassis DRW 4470 [176] 3946 [8700]

(1) 2767 kg [6100 lb] When completed with 6 or less designated seating positions.

(2) Maximum unloaded vehicle weight values shown in this table are limits for purposes of F/CMVSS conformity only. See Emission

Certication information on page 49 for possible additional weight restrictions to meet emission requirements.

TABLE B

MINIMUM SUB WEIGHT

Minimum unloaded vehicle weight for cutaways completed as school buses is dened in Standard 105 requirements on page 11.

Kilogram Model [Pound]

E-350 Cutaway DRW 204 3505mm [138 in] WB [450]

E-350 Cutaway DRW 238 4013mm [158 in] WB [525]

E-350 Cutaway DRW 238 4470mm [176 in] WB [525]

E-450 Cutaway DRW 238 4013mm [158 in] WB [525]

E-450 Cutaway DRW 238 4470mm [176 in] WB [525]

E-350 Basic (Stripped) Chassis DRW 862 All WB [1900]

E-450 Basic (Stripped) Chassis DRW 998 All WB [2200]

E-SERIES (May, 2004) 15

STATEMENTS OF CONFORMITY

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