Ford E-550 User Manual

2002

Important Notice

MARCH 2002

IMPORTANT NOTICE

Index/Features

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.

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 (877) 840-4338  Fax (313) 594-2633  E-Mail bbasqa@ford.com

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.

INDEX/FEATURES

Important Notice/Reference Information

Technical Specifications

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/Tire/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. . . . . . . . . . . . . .

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

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

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

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

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

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

 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.

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Page 2 E-550 SUPER DUTY CUTAWAY

METRIC/U.S. CUSTOMARY UNIT EQUIVALENTS

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 inches

feet

2 2

X 645.16 = millimetres X 6.452 = centimetres2 (cm2) X 0.155 = inches X 0.0929 = metres2 (m2) X 10.764 = feet

(mm2) X 0.00155 = inches

2 2

horsepower X 0.746 = kilowatts (kW) X 1.34 = horsepower ft-lb/min X 0.0226 = watts(W) X 44.27 = ft-lbf/min

TORQUE

VOLUME

inches

X 16387.0 = millimetres3 (mm3) X 0.000061 = inches X 16.387 = centimetres3 (cm3) X 0.06102 = inches X 0.01639 = litres (1) X 61.024 = inches

3 3 3

lb-in X 0.11298 = newton-metres (N-m) X 8.851 = lb-in lb-feet X 1.3558 = newton-metres (N-m) X 0.7376 = lb-feet

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 feet

X 28.317 = litres (1) X 0.03531 = feet X 0.02832 = metres3 (m3) X 35.315 = feet

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

3 3

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

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)

“ ”

VERTICAL TRANSVERSE

PLANE

TYPICAL LONGITUDINAL

PLANE

BB0689

GROUND

“0 ”

PLANE

MM THREE–DIMENSIONAL REFERENCE SYSTEM

HORIZONTAL

PLANE (mm)

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BASE CURB WEIGHT*

SERIES

WHEELBASE

GVWR

STANDARD

ENGINES

4051.3

17,500/19,000

4R100

4508.5

17,500/19,000

4R100

E55

4864.1

17,500/19,000

4R100

5321.3

17,500/19,000

4R100

5930.9

17,500/19,000

4R100

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E-550 SUPER DUTY CUTAWAY

Page 3 E-550 SUPER DUTY CUTAWAY

MODEL

E-550

uper Duty

Cutaway

CODE

mm/inches

4051.3 [159.5]

4508.5 [177.5]

4864.1 [191.5]

MODEL LINEUP

pounds

TRANSMISSION

liters

6.8 3405 2785 6190

7.3 3787 2857 6644

6.8 3475 2844 6319

7.3 3857 2910 6767

6.8 3537 2894 6431

7.3 3921 2958 6879

FRONT

pounds

REAR

pounds

TOTAL

pounds

5321.3 [209.5]

5930.9 [233.5]

* Weight calculated with fuel and fluids to full capacity.

6.8 3617 2959 6576

7.3 4003 3019 7022

6.8 3722 3046 6768

7.3 4112 3102 7214

NOTE  [ ] DIMENSIONS ARE INCHES.

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E-550 SUPER DUTY CUTAWAY

Page 4 E-550 SUPER DUTY CUTAWAY

[2.0]

[1.6]

657 REF

[25.9]

FRONT FIDUCIAL MARK

[0.5]

SEAT TRACK TRAVEL/H-POINT LOCATION

DRIVER

POWER TRACK

175

[6.9]

155

[6.1]

150

[5.9]

SgRP

MID–TRACK H POINT

208

[8.2]

388 REF

[15.3]

[3.3]

[0.4]

[0.7]

[0.1]

[1.1]

[1.3]

[0.4]

FOREMOST H POINT

[0.9]

657 REF

[25.9]

FRONT FIDUCIAL MARK

DRIVER

MANUAL TRACK

MID–TRACK H POINT

168

[6.6]

388 REF

[15.3]

178

[7.0]

SgRP

[3.5]

[0.4]

1.4

[0.05]

REARMOST H POINT

BB0056

FOREMOST H POINT

[0.9]

650 REF

[25.6]

FRONT FIDUCIAL MARK

FRONT PASSENGER

MANUAL TRACK

MID–TRACK H POINT

168

[6.6]

447 REF

[17.6]

178

[7.0]

SgRP

[3.5]

[0.4]

1.4

[0.05]

REARMOST H POINT

FRONT PASSENGER MANUAL TRACK

FOREMOST H POINT

[0.7]

653 REF

[25.8]

FRONT FIDUCIAL MARK

FIXED SEAT BACK

MID–TRACK H POINT

427 REF

[16.8]

129

[5.1]

[2.3]

[0.4]

139

[5.5]

SgRP

NOTES —

NOTES  [ ] DIMENSIONS ARE INCHES.

1.4

[0.05]

REARMOST H POINT

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 LOCA TION MUST BE MAINTAINED IN ORDER TO COMPLY WITH FMVSS 208 AIRBAG REQUIREMENTS.

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E-550 SUPER DUTY CUTAWAY

OCCUPANT PROTECTION SYSTEMS

SEAT RESTRAINT SYSTEM

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

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.

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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

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.

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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. T O 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 INJUR Y IN THE EVENT OF A COLLISION.

OCCUP ANT 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

representations.)

for these compliance

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