Page 1
2002
Important Notice
MARCH 2002
Page 2
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.
Page 3
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.
Page 4
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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
2
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
2
(mm2) X 0.00155 = inches
2
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
3
inches
3
inches
3
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
3
feet
feet
3
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
X
TYPICAL LONGITUDINAL
Y
PLANE
BB0689
GROUND
“0 ”
Z
PLANE
MM THREE–DIMENSIONAL REFERENCE SYSTEM
HORIZONTAL
PLANE (mm)
Z
Page 5
click
BASE CURB WEIGHT*
SERIES
WHEELBASE
GVWR
STANDARD
ENGINES
4051.3
17,500/19,000
4R100
4508.5
17,500/19,000
4R100
S
E55
4864.1
17,500/19,000
4R100
y
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
p
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.
Page 6
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E-550 SUPER DUTY CUTAWAY
Page 4 E-550 SUPER DUTY CUTAWAY
51
41
[2.0]
[1.6]
657 REF
[25.9]
FRONT FIDUCIAL
MARK
13
[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]
84
[3.3]
10
[0.4]
18
[0.7]
25
[0.1]
[1.1]
33
[1.3]
28
10
[0.4]
FOREMOST
H POINT
24
[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]
89
10
[0.4]
1.4
[0.05]
REARMOST
H POINT
BB0056
FOREMOST
H POINT
24
[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
89
[3.5]
10
[0.4]
1.4
[0.05]
REARMOST
H POINT
FRONT PASSENGER MANUAL TRACK
FOREMOST
H POINT
18
[0.7]
653 REF
[25.8]
FRONT FIDUCIAL
MARK
FIXED SEAT BACK
MID–TRACK
H POINT
427 REF
[16.8]
129
[5.1]
59
[2.3]
10
[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.
nnn
Page 7
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Page 5 E-550 SUPER DUTY CUTAWAY
TO RETURN TO INDEX
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.
Ford Truck Shop
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.
Ford Truck Shop Manual
.
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
Page 8
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Page 6 E-550 SUPER DUTY CUTAWAY
E-550 SUPER DUTY CUTAWAY
OCCUPANT PROTECTION SYSTEMS
SEAT RESTRAINT SYSTEM
F65B–15602B90
XC2A–15602B82
ADJ. ASY.
FRONT OF
VEHICLE
+
PIA
BOLT–TORQUE
+
40.0 6.0 Nm
–
+
[29.5 4 ft–lb]
–
COVER ASY .
PANEL ASY.
UPPER
F7UB–1560262
COVER ASY .
1 REQ’D. EA. SIDE
N806773–S190
NUT – TORQUE
40.0 6.0 Nm
15611B09
BEL T AND
RETRACTOR ASY.
ALL CUTAWAY
MODELS ONLY
368273–S100
BOLT TORQUE
40 6 Nm
FRONT OF
VEHICLE
PIA
BOLT–TORQUE
+
40.0 6.0 Nm
–
+
[29.5 4 ft–lb]
–
B
A
VIEW
SHIPPING CLIP MUST
REMAIN CLIPPED TO
BELT PRIOR TO
ATTACHMENT TO
RETRACTOR INTO
VEHICLE.
ALL WAGON – VAN MODELS ONLY
DRIVER – SEAT
(LEFT HAND) INSTALLATION
A
A
ALL CUTAWAY
PANEL ASY. COVER
VIEW
B
CRITICAL CONTROL ITEM
MODELS ONLY
ALL WAGON – VAN MODELS ONLY
PASSENGER SEAT
(RIGHT HAND) INSTALLATION
XC2A–15602B82
ADJ. ASY.
CUTAW AY & VAN MODELS
SHIPPING CLIP MUST
REMAIN CLIPPED TO
BELT PRIOR TO
ATTACHMENT TO
RETRACTOR INTO
VEHICLE.
CRITICAL CONTROL ITEM
F65B–602B90
COVER ASY .
F7UB–1560262
COVER ASY .
1 REQ’D. EA. SIDE
N806773–S190
NUT – TORQUE
40.0 6.0 Nm
611B08
BEL T AND
RETRACTOR ASY.
VIEW
A
PANEL ASY.
COVER
(3) FULL
THREAD
EXPOSED
SECTION A–A
9.5 RADIUS MIN.
UP
ADJUSTED
POSITION
DOWN
ADJUSTED
POSITION
6.0 MIN. CLEARANCE
TO ALL ADJUSTED
POSITIONS
13.0 MIN. FROM
COVER TO
RELEASE KNOB
2.0 MIN.
(WITH D–RING
LOCATED ON
SHLDR.BOLT)
1560262 REF.
INTERIOR TRIM
12.5 MIN.
OVERLAP
RETRACTOR
6.5 MIN. FROM
RELEASE KNOB
TO INTERIOR TRIM
MAIN VIEW
SECTION D–D
FRONT OF
VEHICLE
6.0
SECTION B–B
UP POSITION
6.0 MIN.
6.0 MIN. CLEARANCE
AROUND BELT
PERIPHERY AT MAX.
TRAVEL POSITIONS
SEAT BELT
WEBBING
6.0 MIN.
3.0
BB0464
RESTRAINT SYSTEM INSTALLATION
LH DRIVER SEAT
SEAT RESTRAINT SYSTEM INSTALLATION
RH PASSENGER
FRONT SEATS RESTRAINT INSTALLA TION
NOTE - [ ] DIMENSIONS ARE FT -LB OR INCHES.
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Page 7 E-550 SUPER DUTY CUTAWAY
SEA T ASY.
PIA BOLT
TORQUE
40.0 6.0 Nm
[29.5 4 FT-LB]
N801078–S424
SCREW M8 x 1.25 HEX
4 REQ’D.
TORQUE 25.0 3.8 Nm
[18.4 2.8 FT-LB]
F7UB–14A699–A
WIRE ASY .–
ST. CONTROL
N800937–S424
SWITCH ASY.
ST. CONTROL
M2003089
SUPPORT ASY .
611D02–A
STUD COVER
4 REQ’D.
BB0475
N811326–S424
SCREW 2 REQ’D.
55.0 8.3 Nm
[40.6 6 FT-LB]
POWER LH SHOWN
NUT & WASHER ASY.
2 REQ’D.
55.0 8.3 Nm
[40.6 6 FT-LB]
N802351–S424
STUD 2 REQ’D.
N620481–S58
NUT M8 x 1.75 HEX FLANGE
TORQUE 25.0 3.8 Nm
[18.4 2.8 FT-LB]
M200751
TRACK ASY .
FRT. ST.
56912–S58
SCREW 4.2 x 19
TAPPING
A2008168
TRACK ASY .
F7UB–1561755–A
HANDLE FRT. ST.
TRACK
F7US–14A699–DB
WIRE ASY .
F7UB–1562506–A
SUPPORT ASY .
(R.H. MNL)
611D02–A
STUD COVER
4 REQ’D.
E-550 SUPER DUTY CUTAWAY
OCCUPANT PROTECTION SYSTEMS
SEAT RESTRAINT SYSTEM
SEA T ASY.
PIA BOLT
TORQUE
40.0 6.0 Nm
[29.5 4 FT-LB]
F7UB–1561202–A
BUCKLE ASY .
COVER FRT
ST . PVT.
A2008170 DRIVER
A2008168 PASS.
R.H. TRACK
N811326–S424
SCREW 2 REQ’D.
55.0 8.3 Nm
[40.6 6 FT-LB]
F7US–14A699–DB
WIRE ASY .
F7UB–1561755–A
HDL.FRT .ST.TRK.
F7UB–1567506–A
SUPPORT ASY .
N811326–S424
SCREW 2 REQ’D.
55.0 8.3 Nm
[40.6 6 FT-LB]
POWER RH SHOWN
N801078–S424
SCREW M8x1.25
HEX 4 REQ’D.
TORQUE
25.0 3.8 Nm
[18.4 2.8 FT-LB]
A2008167
TRACK ASY .
F7UB–1561202–A
PYROTECHNIC
ASY. R.H.
PIA BOLT
TORQUE
40.0 6.0 Nm
[29.5 4 FT-LB]
COVER–FRT.
ST . PIVOT
36912–S58
SCREW 4.2 x 19.0
TAPPING
N802351–S424
STUD 2 REQ’D.
N620482–S424
M10 HEX NUT HD.
NUT W/WASHER
4 REQ’D.
T2007563
SEAT
NUTS & BOLTS 4 REQ’D.
FOR SHIPPING
PURPOSES
ONLY
611D02–A
STUD COVER
4 REQ’D.
N800937–S424
NUT & WASHER ASY.
2 REQ’D.
55.0 8.3 Nm
[40.6 6 FT-LB]
A2008169 DRIVER
A2008167 PASS.
R.H. TRACK
N802351–S424
STUD 2 REQ’D.
CLEARANCE
ZONE
10
15
SIDE VIEW REAR VIEW
FRONT OF VEHICLE
VIEW A
PRETENSIONER CLEARANCE ZONE
IMPORTANT:
THE SHADED AREA MUST BE FREE OF OBSTRUCTIONS.
THE BUCKLE MOVES DOWNWARD THROUGH THE SHADED
ZONE AND MUST NOT CONTACT ANY COMPONENT WHICH
MAY DEGRADE ITS PERFORMANCE.
DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADED
AREA, OR ALTER OR MODIFY THIS AREA.
CLEARANCE
10
ZONE
CENTER OF VEHICLE
45
LH DRIVER
SEAT INSTALLATION
RH PASSENGER
SEAT INSTALLATION
LH DRIVER
SEAT DELETE OPTION
NOTE - DIMENSIONS ARE FT -LB OR INCHES.
Page 10
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Page 8 E-550 SUPER DUTY CUTAWAY
TO RETURN TO INDEX
INFORMATION
Ford urges careful consideration of the
recommendations that follow. They are based on
analyses of component and vehicle tests, actual
service situations, and engineering judgments.
Disregard of these recommendations may affect the
durability, reliability, handling and performance
characteristics of a completed vehicle and may result
in elevated underbody temperatures, increase the
potential for fire, or may affect the safety of the
occupants in the event of an accident.
These recommendations are supplemental to U.S.
and Canadian Motor Vehicle Safety compliance
representations provided in the
Manua
l (IVM). Also, additional information is provided
in the
helpful to subsequent stage manufacturers.
The completed vehicle in the “Loaded” condition must
not exceed the front GAWR, rear GAWR, or the GVWR.
(“Loaded” means the completed vehicle weight with the
maximum fluid capacity necessary for vehicle operation,
plus 150 lb for each designated seating position, and
an additional allowance for any cargo weight
advertised by the manufacturer). The GAWRs and
GVWR are on the label affixed to the cover of the
Ford Truck Service Manual
Incomplete Vehicle Manual
Subsequent Stage Manufacturers are encouraged
to contact the Ford Truck Body Builder Advisory
Service if they have any questions concerning
these recommendations.
Incomplete Vehicle
which may be
.
E-550 SUPER DUTY CUTAWAY
OCCUPANT PROTECTION SYSTEMS
AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM
AIRBAG SUPPLEMENTAL RESTRAINT
SYSTEM
Some trucks produced by Ford Motor Company are
equipped with an Airbag Supplemental Restraint
System (SRS). Vehicles equipped with this system
will have the words “AIRBAG” and an air bag symbol
on the VIN plate located on the top driver-side corner
of the instrument panel. System components are
shown in their vehicle locations on the following
pages.
Included on the vehicle identification number -VINplate (visible through the windshield) of the vehicle,
manufactured by Ford with a driver’s air bag, are the
words “AIR” and “BAG” and a pictogram for the airbag
separating the two (see illustration below).
AIR BAG
SAMPLEXXXXXXXXXXX
BB0538
Detailed system and service information will be found
Ford Truck Service Manual
in the
type and model year. Ford Motor Company urges the
subsequent stage manufacturers to become familiar
with this system prior to modifying vehicles that are so
equipped.
CAUTION:
DO NOT REMOVE THE STEERING COLUMN,
STEERING WHEEL AND AIRBAG MODULE AS AN
ASSEMBLY FROM THE VEHICLE UNLESS (1) THE
COLUMN IS LOCKED TO PREVENT ROTATION, OR
(2) THE LOWER END OF STEERING SHAFT IS
SECURED (e.g., by wire) IN SUCH A WAY THAT THE
STEERING WHEEL CANNOT BE ROTATED.
for the appropriate
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.
If electrical work is performed in the steering column
area, the instrument panel or the air bag system, the
system must be deactivated to avoid unwanted
inflation of the air bag. To do this, follow the procedure
described on this page.
DEACTIVATION PROCEDURE
1. Disconnect all negative battery cable(s), and
power supplies (if equipped).
2. Wait 1 minute. This is the time required for
backup power supply in diagnostic monitor to
deplete its stored energy.
WARNING:
TO AVOID ACCIDENTAL DEPLOYMENT AND
POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE
REPAIRING OR REPLACING ANY AIRBAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
COMPONENTS. TO DEPLETE THE BACKUP
POWER SUPPLY ENERGY, DISCONNECT THE
BATTERY GROUND CABLE AND WAIT ONE
MINUTE. BE SURE TO DISCONNECT
AUXILIARY BATTERIES AND POWER
SUPPLIES (IF EQUIPPED).
WARNING:
CARRY A LIVE AIRBAG MODULE WITH THE
AIRBAG AND TRIM COVER POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE
RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
WARNING:
DO NOT SET A LIVE AIRBAG MODULE DOWN
WITH THE TRIM COVER FACE DOWN.
3. Remove fasteners retaining driver airbag
module to steering wheel. Disconnect driver
airbag connector and remove the bag from
steering wheel. Place the bag on a flat surface
with trim cover facing upward. Connect an
Airbag Simulator (Part # 105-R0012 in the
Rotunda Tool catalog) to the air bag connector
on the wire harness in the steering wheel.
4. Disconnect passenger airbag module connector
and replace it with an Airbag Simulator (Part #
105-R0012 in the Rotunda Tool catalog) to the
airbag connector on the wire harness in the I/P.
5. Reconnect all negative battery cables and
power supplies (if equipped).
REACTIVATION PROCEDURE
1. Disconnect all negative battery cable(s) and
power supplies (if equipped).
2. Wait 1 minute for backup power supply to
deplete stored energy.
3. Remove Airbag Simulator and reconnect driver
airbag connector. Position driver airbag on
steering wheel and secure with fasteners
(10mm). Tighten fasteners to 2.7-3.7 Nm.[24-32
in-lb].
4. Remove Airbag Simulator and reconnect
passenger airbag connector.
5. Reconnect all negative battery cables and
power supplies (if equipped).
6. PROVE-OUT the system.
PROVE-OUT SYSTEM PROCEDURE
Prove-out system means to turn the ignition switch
from OFF to RUN and visually monitor the airbag
indicator. The airbag will light continuously for
approximately six seconds and then turn off. If an
airbag system fault is present, the indicator will
either fail to light, remain lit continuously or light in a
flashing manner. The flashing manner may not
occur until approximately 30 seconds after the
ignition switch has been turned from OFF to RUN.
This is the time required for the diagnostic monitor
to complete the testing of the airbag system. If the
airbag indicator is inoperative and an airbag
system fault exists, a tone will sound in a pattern of
five sets of five beeps. If this occurs, the airbag
indicator will need to be serviced before further
diagnosis can be done.
Page 11
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TO RETURN TO INDEX
Page 9 E-550 SUPER DUTY CUTAWAY
E-550 SUPER DUTY CUTAWAY
OCCUPANT PROTECTION SYSTEMS
AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM
AIRBAG USAGE CHART
VEHICLE DRIVER PASSENGER
E-550 Super Duty Cutaway Standard Front Standard Front
DO NOT INSTALL ADDITIONAL COMPONENTS IN THE
SHADED AREAS, OR ALTER OR MODIFY THESE AREAS.
BB0466
INSTRUMENT
PANEL HARNESS
AIRBAG
ELECTRONIC
CRASH SENSOR
MODULE
CRASH
SENSOR
DO NOT MODIFY OR ALTER ANY COMPONENTS OR AREAS
OF THE VEHICLE IN THE VICINITY OF THE COMPONENTS
THAT ARE IDENTIFIED IN THIS ILLUSTRATION.
STEERING
WHEEL
AIRBAG
READINESS
INDICATOR
CONNECTOR
AT SAFETY
WALL
ENGINE
COMPARTMENT
HARNESS
Page 12
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TO RETURN TO INDEX
Page 10 E-550 SUPER DUTY CUTAWAY
2605
[102.5]
MIRRORS
2754
[108.4]
EXTENDED
FLARES
2203
[86.7]
VEHICLE
BUMPER
C
L
2186
[86.0]
1st BATTERY
LOCATION
2016
[79.3]
DIMENSIONAL DATA
E-550 SUPER DUTY CUTAWAY
159.5 - 233.5 WHEELBASE (DRW)
716
[28.2]
2nd BATTERY
LOCATION
955
[37.6]
SEE NOTES
1083
[42.6]
1067
[42.0]
55 GAL STD FUEL TANK
2456
[96.7]
475
[18.7]
BB0688
CH
132
[5.2]
657
44
[1.8]
[25.9]
C
L
REAR AXLE
1510
[59.4]
1575 DRIVER SEAT
(REARMOST)
[62.0]
TOP OF FRAME KICKUP
F
B
A
[25.0]
736
625
[29.0]
C
L
FRONT AXLE
WHEELBASE
AT OF REAR AXLEC
L
NORMAL T OP
OF FRAME
OVERALL LENGTH
CA
1658.9
[65.3]
740
[29.1]
CH
DIMENSIONS
WB
[159.5]
[177.5]
[191.5]
[209.5]
[233.5]
R
REAR OVERHANG
NOTES [ ] DIMENSIONS ARE INCHES.
NOTES A, B, F, R DIMENSIONS, SEE PAGE 11.
NOTES 25 MM CLEARANCE IS REQUIRED BETWEEN ALL FUEL TANK COMPONENTS AND
NOTES SECOND UNIT BODY. CONTACT BODY BUILDERS ADVISORY SERVICE FOR NOTES
NOT ESINFORMATION.
CA
2540 [100.0]
2997 [118.0]
3353 [132.0]
3810 [150.0]
4420 [174.0]
AF
AF REAR
OVERHANG
1948.8 [76.7]
1948.8 [76.7]
2133 [84.0]
2438 [96.0]
2895 [114.0]
FUEL FILLER LOCATION
OVERALL
LENGTH
6736 [265.2]
7193 [283.2]
7734 [304.5]
8496 [334.5]
9563 [376.5]
EXHAUST OUTLET
OVERALL
CURB LOADED
2270 [89.3]
2270 [89.3]
2270 [89.3]
2270 [89.3]
2270 [89.3] 2201 [86.6]
411
[16.2]
HEIGHT
2201 [86.6]
2201 [86.6]
2201 [86.6]
2201 [86.6]
Page 13
click
A
B
C
OVERALL
STD
STD
here
TO RETURN TO INDEX
Page 11 E-550 SUPER DUTY CUTAWAY
E-550 SUPER DUTY CUTAWAY
VEHICLE HEIGHT DATA
TIRE/GROUND CLEARANCE DATA
F F R R CH
HEIGHT @
FRONT AXLE
HEIGHT @
(1)
FRONT AXLE
(1)
HEIGHT @
REAR AXLE
(1)
REAR AXLE
HEIGHT @
OVERALL HEIGHT
(1)
OF VEHICLE
(STANDARD SPRINGS)
(1)
COMBINED
FRONT SPRING
CAPACITY RATE
GVWR
pounds
standard/
MODEL WB
E-550
SUPER DUTY
ALL
CUTAWAY
(1)
— The Height Data shown represents dimensions of a nominal vehicle with no options. Actual height may vary due to production tolerances.
G
GROUND
LINE
BB0684
optional
17,500
19,000
APPROACH ANGLE
AT GVWR
MINIMUM TIRE
225/70R19.5F 6000 6000 772 [30.3] 703 [27.6] 11,500/13,500 11,500/13,500
FRONT GAWR
162
[6.4]
899
[35.4]
1198
[47.2]
MIN/MAX
pounds
@ GROUND
pounds
STD SPRING STD SPRING STD SPRING STD SPRING STD SPRING STD SPRING
“A” STATIC LOADED RADIUS
BASE CURB
WEIGHT
mm [in]
“B” TIRE DIAMETER
182
[7.2]
LOADED
mm [in]
REAR GAWR
MINIMUM GROUND CLEARANCE LINE
AT GVWR (LOADED) – COMPONENTS
THAT COULD DISABLE A VEHICLE
SHOULD BE 30.0 [1.18] ABOVE THE
MINIMUM CLEARANCE LINE.
MIN/MAX
pounds
standard/
optional
162
[6.4]
1198 [47.2]
COMBINED
REAR SPRING
CAPACITY RATE
@ GROUND
899 [35.4]
pounds
BASE CURB
WEIGHT
mm [in]
817.8
[32.2]
LOADED
mm [in]
UNLOADED
725.0
[28.5]
DEPAR TURE ANGLE
AT GVWR
mm [in]
2270
[89.3]
LOADED
mm [in]
2201
[86.6]
J
MODEL TIRE SIZE
E-550 225/70R19.5F
STATIC
LOADED
RADIUS
378
[14.9]
ALL SEASON TIRE DATA
MAX.
DIAMETER
811
[31.9]
MAX.
SECTION
WIDTH
226
[8.9]
RIM
WIDTH
152
[6.0]
BASE VEHICLE UNLOADED CURB WEIGHT
TREAD WIDTH
FW RW
FRONT REAR REAR SPRING SPRING
1999
[78.7]
1970
[77.5]
OW TH TW
OVERALL
WIDTH
2456
[96.7]
205.7
[8.1]
708
[27.9]
GROUND CLEARANCE
G J
APPROACH ANGLE DEPARTURE ANGLE
159.5WB177.5WB191.5WB209.5WB233.5WB159.5WB177.5WB191.5WB209.5WB233.5
WB
33° 33° 33° 33° 33° 15.9° 15.9° 14.5° 12.6° 10.6°
NOTE [ ] DIMENSIONS ARE INCHES.
Page 14
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E-550 SUPER DUTY CUTAWAY
Page 12 E-550 SUPER DUTY CUTAWAY
25.1
195
[7.6]
FW
VEHICLE
FRONT VIEW
ALL WHEELBASES
C
L
215
[8.4]
1970
[77.5]
VEHICLE
25.4 MIN.
[1.0] CLEARANCE
REAR VIEW
TW
2456
[96.7]
12.7 MIN. CLEARANCE
TW
1
TH
1
248
[9.8]
C
L
C
[0.5]
25.4 MIN. CLEARANCE
[1.0]
212.3
[8.3]
C
271
[10.6]
0.5 MIN.
CLEARANCE
TH
27.9
[1.1]
NORMAL
TOP OF FRAME
25.1
BB0685
C
L
VEHICLE
TW
L
TW
R
PLAN VIEW
LEFT FRONT TIRE
= DISTANCE FROM
TW
SIDE OF TIRE IN MODIFIED JOUNCE.
= DISTANCE FROM TOP OF FRAME
TH
SPACERS T O T OP OF TIRE IN
MODIFIED JOUNCE.
MAX. RIGHT TURN
MAX. LEFT TURN
C
OF VEHICLE TO
L
225/70R/19.5F
TW TH
11TWLTWR
838 213 640 668
[33.0] [8.4] [25.2] [26.3]
NOTES [ ] DIMENSIONS ARE INCHES.
NOTES C, FW, TW, TH DIMENSIONS, SEE PAGE 11.
Page 15
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TO RETURN TO INDEX
Page 13 E-550 SUPER DUTY CUTAWAY
952
[37.4]
847
[33.3]
613
[24.1]
E-550 SUPER DUTY CUTAWAY
159.5 WHEELBASE FRAME DATA
BODY PUCKS
1230
[48.4]
1460
[57.5]
813
[32.0]
381
[15.0]
NOTE: SPACER OPTIONS NOT AVAILABLE ON
E–550. CONTACT BODY BUILDERS ADVISORY
SERVICE FOR INFORMATION REGARDING THE
PURCHASE OF SPACERS.
TOP OF FRAME
BB0679
159.5 WB
48.9 FREE
BOLTS & BODY
MOUNTS IN
DUNNAGE
PACKAGES
TORQUE TO
70 +/– 10.5 Nm
BODY PUCKS (OPTIONAL)
43.5 [1.7] FREE
(32.6 [1.2] w/LOAD)
STATE[1.9]
107.3 FREE
[4.2]
56.8 [2.2] FREE
(54.2 [2.1] w/LOAD)
35.7
DIA HOLE IN FRAME
[1.4]
SHIPPED IN DUNNAGE
TOP OF FRAME
47.0 FREE
STATE
[1.8]
BOLTS & BODY
MOUNTS IN
DUNNAGE
PACKAGES
TORQUE TO
70 +/– 10.5 Nm
NOTES [ ] DIMENSIONS ARE INCHES.
NOTES C, CH, FW DIMENSIONS, SEE PAGE 11.
41.6 [1.6] FREE
(32.6 [1.2] w/LOAD)
102.7 FREE
54.1 [2.1] FREE
(54.1 [2.1] w/LOAD)
35.7
DIA HOLE IN FRAME
[1.4]
[4.0]
Page 16
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here
Page 14 E-550 SUPER DUTY CUTAWAY
TO RETURN TO INDEX
952
[37.4]
847
[33.3]
613
[24.1]
E-550 SUPER DUTY CUTAWAY
177.5 - 191.5 WHEELBASE
FRAME DATA
1231
[48.4]
1460
[57.4]
527
[20.7]
743
[29.3]
381
[15.0]
BB0680
BB0681
177.5 WB
952
[37.4]
191.5 WB
847
[33.3]
462
[18.2]
677
[26.6]
1099
[43.2]
381
[15.0]
1460
[57.5]
1353
[53.2]
NOTE: SPACER OPTIONS NOT AVAILABLE ON
E–550. CONTACT BODY BUILDERS ADVISORY
SERVICE FOR INFORMATION REGARDING THE
PURCHASE OF SPACERS.
NOTE [ ] DIMENSIONS ARE INCHES.
Page 17
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here
Page 15 E-550 SUPER DUTY CUTAWAY
TO RETURN TO INDEX
952
[37.4]
847
[33.3]
462
[18.2]
E-550 SUPER DUTY CUTAWAY
209.5 - 233.5 WHEELBASE
FRAME DATA
1460
[57.4]381
677
[26.6]
822
[32.3]
734
[28.9]
[15.0]
1353
[53.2]
305
[12.0]
209.5 WB
BB0682
233.5 WB
BB0683
952
[37.4]
847
[33.3]
462
[18.2]
677
[26.6]
822
[32.3]
1344
[52.9]
381
[15.0]
1460
[57.4]
762
1353
[53.2]
[30.0]
NOTE: SPACER OPTIONS NOT AVAILABLE ON
E–550. CONTACT BODY BUILDERS ADVISORY
SERVICE FOR INFORMATION REGARDING THE
PURCHASE OF SPACERS.
NOTE [ ] DIMENSIONS ARE INCHES.
Page 18
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TO RETURN TO INDEX
E-550 SUPER DUTY CUTAWAY
Page 16 E-550 SUPER DUTY CUTAWAY
55 GALLON AFT-OF-AXLE FUEL TANK
A
939.8
[37.0]
BB0693
C
L
REAR AXLE
A
822.9
[32.4]
374.6
[14.7]
C
L
FUEL FILL
25mm CLEARANCE IS REQUIRED BETWEEN
ALL FUEL TANK COMPONENTS AND
SECOND UNIT BODY. CONTACT BODY BUILDERS
ADVISORY SERVICE FOR INFORMATION.
40.6
[1.6]
363.2
[14.3]
330.2
[13.0]
A
988.0
[38.9]
NOTE [ ] DIMENSIONS ARE INCHES.
Page 19
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TO RETURN TO INDEX
E-550 SUPER DUTY CUTAWAY
Page 17 E-550 SUPER DUTY CUTAWAY
FRONT OF VEHICLE
FUEL FILLER SYSTEMS
E-550 CUTAWAY
AFT-OF-AXLE FUEL FILLER SYSTEM
C
C
TO L OF REAR
AXLE FOR
ALL W.B.
823
[32.4]
733.4
[28.875]
SCREW 3 REQ’D.
TORQUE TO 2.1 – 2.9 Nm
18 – 26 IN LB.
TOP OF
FILLER
PIPE
SUPPORT
323.2
[12.72]
L OF FILLER NECK
OUTBOARD SURFACE
OF FRAME RAIL
FUEL TANK
SECURE WITH TIE
STRAPS AS REQUIRED
TO VENT HOSE
FRONT OF
VEHICLE
5
3
2
6
TORQUE SEQUENCE
1
4
POINT Z SEE PAGE 59
OF THE INCOMPLETE
VEHICLE MANUAL
BB0678
FUEL TANK
FILL PIPE
N611131–S36
M4 SELF–TAPPING
SCREW
TORQUE ALL WORM GEAR DRIVEN
HOSE CLAMPS TO 2.8 - 4.3 Nm
25 – 38 IN LBS.
N611645–S36
M10 SELF–TAPPING SCREW
(ATTACH TO SOUND
METAL ON FRAME)
CRITICAL CONTROL ITEM
FUEL RETURN
FUEL SUPPLY
LINE
AUXILIARY FUEL SUPPLY
(DO NOT REMOVE CAP
IF NOT IN USE)
FUEL TANK STUDS
40.2
[1.583]
EXISTING 9.7 DIA. HOLES
(USED FOR EXHAUST
ON R.H. SIDE)
VIEW A
ROUTE FILL AND VENT
HOSE SO NO LOW
SPOTS OCCUR
9A099
GROUND STRAP
FUEL TANK
NUT 6 REQ’D.
TORQUE TO
13.7 – 17.3 Nm
120 – 153 IN LB.
FUEL PUMP/FUEL GAUGE
SENDING UNIT
NOTE: USE A NEW O–RING
GASKET WHEN REINSTALLING
THE FUEL PUMP/FUEL GAGE
SENDING UNIT.
NOTE [ ] DIMENSIONS ARE INCHES.
Page 20
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E-550 SUPER DUTY CUTAWAY
Page 18 E-550 SUPER DUTY CUTAWAY
POINT A
SEAT
BASE
PASSENGER – SEAT DRIVER – SEAT
E
B
C
OUTSIDE
L
FRONT
FASTENER
W3
W5
W117
C
VEHICLE
L
C
OUTSIDE
L
FRONT
FASTENER
DIMENSIONAL DATA
THE TORSO ANGLE IS DETERMINED BY
USING THE METHOD SPECIFIED IN
SAE J826 (MAY 1987)
C
OUTSIDE
L
FRONT
FASTENER
E
B
POINT A
SEAT
BASE
6.0
[0.24]
HEEL
POINT
L34
510.0
[20.08]
A
D
H61
C
18 DRIVER
21 PASSENGER
TORSO ANGLE
POINT A
F
SEAT BACK
PIVOT
SgRP - HAS A 12.7 [0.50] RADIAL
TOLERANCE PERMITTED FROM
BASE SgRP
IMPORTANT:
THE DIMENSIONS IN THIS FIGURE REQUIRE THE VEHICLE TO BE AT
DESIGN POSITION. E–SERIES VEHICLES AT DESIGN POSITION
WILL BE LEVEL FRONT T O REAR, AND SIDE TO SIDE, ON THE UPPER
SURFACE OF THE RIBBED FLOOR PANEL FROM THE B–PILLAR REARWARD.
BB0686
SgRP INFORMATION
(SEAT POSITION IS 10.0 [0.39] FORWARD OF
REARMOST POSITION)
A B C D E F
DRIVER - SEAT (CUTAWAY) 217.8 [8.57] 105.0 [4.13] 384.2 [15.13] 356.0 [14.01] 67.0 [2.64] 937.4 [36.90]
PASSENGER - SEAT (CUTAWAY) 277.3 [10.92] 103.0 [4.06] 377.0 [14.84] 412.0 [16.22] 65.0 [2.56] 960.0 [37.80]
POINT A
(SEAT POSITION IS AT THE MIDPOINT OF
AVAILABLE TRAVEL)
DRIVER SIDE ONLY
CODE DESCRIPTION
FRONT COMPARTMENT
L34
W3
W5
W1 17 BODY WIDTH AT H–POINT
H61
MAXIMUM EFFECTIVE LEG ROOM – FRONT
SHOULDER ROOM – FRONT
HIP ROOM – FRONT
EFFECTIVE HEAD ROOM – FRONT
NOTE [ ] DIMENSIONS ARE INCHES.
DIMENSIONS
1015 [39.9]
1736 [68.3]
1666 [65.6]
1999 [78.7]
1079 [42.5]
Page 21
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E-550 SUPER DUTY CUTAWAY
Page 19 E-550 SUPER DUTY CUTAWAY
0
1.97
1.20
3.94
7.87
1.97
11.81
15.75
19.68
23.62
27.56
31.50
35.43
39.37
1.18
1.03
1.97
0.35
0.40
1.97
1.97
1.91
0.90
1.14
1.26
1.16
1.16
1.16
0.77
1.00
0.83
0.75
0.35
0.59
0.44
0.27
0.20
0.59
0.53
0.21
0.81
0.92
0.07
2.30
2.38
1.97
1.97
C
OF VEHICLE
L
0.87
0.22
1.97
0.40
1.14
2.48
BODY “SECTION A”
1.97
1.97
1.97
2.03
1.61
1.25
0.92
1.97
0.40
0.65
0.08
1.97
0.02
0.22
0.41
0.04
1.97
3.70
0.03
0.07
1.97
0.66
0.09
A
0.08
A
1.97
0.02
TOP OF FRAME
3.84
1.97
SPACERS
0.36
0.25
3.31
3.01
0.53
3.23
1.12
3.17
3.03
2.64
3.07
9.45
0.94
1.97
1.85
0.18
1.97
0.41
1.36
1.53
27.56
0.49
31.50
2.11
35.43
39.37
0.44
0.29
BB0671
51.1855.1259.0563.066.9370.3774.8078.7482.68
47.24 43.30 39.37 35.43 31.50 23.62 19.68
27.56
NOTE DIMENSIONS ARE INCHES.
NOTE DIMENSIONS SHOWN ARE INCHES.
Page 22
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here
TO RETURN TO INDEX
ELECTRICAL WIRING
Page 20 E-550 SUPER DUTY CUTAWAY
Circuit
Number
14 BR 18 Marker lamp feed to electric brake controller
43 DB 12 Electric trailer brake controller to trailer
49 OG 12 Relay feed ignition run
22 LB/BK 12 Trailer brake controller or B+ feed
52 YE 16 Fused left hand stop/turn
64 DG 16 Fused right hand stop/turn
206 W 16 Ground
511 LG 18 Center high mount or lamp feed stop
962 BR/W 16 Relay feed marker lamps
963 BK/LG 16 Relay feed backup lamp
867 DB 12 Customer pass thru circuits
868 GY/R 12 Customer pass thru circuits
53 BK/LB 18 Courtesy lamps
54 LG/YE 18 Courtesy switch feed
3 LG/WH 18 Left turn signal
2 WH/LB 18 Right turn signal
37 YE 12 Battery feed
517 BK/WH 12 Fused feed
751 DB/W 12 Aux. Sw. med hi
752 YE/RD 12 Aux. Sw. med lo
754 LG/WH 12 Aux. Sw. RR Con
757 RD/WH 18 Aux. Sw. hi
Color Code Wire
Gauge
CIRCUIT CHART
CUSTOMER ACCESS CIRCUITS
Functional Description
BB0481
TO INST ALL
UNWRAP TAPE FROM
HARNESS IN THIS AREA
AND REMOVE JUMPER
CONNECTION TO EXPOSE
THE “CHMSL CONNECTOR” .
E-SERIES SUPER DUTY CUTAWAY
FIGURE A
“CHMSL”
FRONT OF
VEHICLE
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