F-SERIES EXCURSION Expedition E-SERIES

FOR 2002FOR 2002

North American TruckSpecial Vehicle Engineering

2002 Ford Truck “What’s New” Guide

The purpose of this guide is to provide some advance insight into 2002 modelyear Ford Truck product features that may assist final stage manufacturers, andvehicle alteration companies, in preparing their production process.

This guide is for reference only, reflecting information available as of September,2001 and is subject to change without notice. It should be used in conjunctionwith other related Ford publications listed below. Methods to obtain these andother useful publications are described further in this manual.

• Ford Truck Body Builders Layout Book• Incomplete Vehicle Manual

This manual is the property of Ford Motor Company. Reproduction or use for any other purpose, without the permission of Ford Motor Company, is prohibited.

TABLE OF CONTENTS

Page Number Subject

1 Body Builder Quality Programs1 Job #1 Timing

2-3 F-1504-5 F-250/350/450/550 Super Duty

6 PTO Circuit Installation, Electrical Wiring7 Trailer Tow Wiring Tap Schematic8 Schematic for Adding Lights or Electrical Devices9 F-650 Super Duty

10 F-750 Super Duty11 F-53 Class A Motorhome Chassis

12-13 E-Series Van / Cutaway / Stripped Chassis14-15 E-550 Super Duty Cutaway

16 E-Series Customer Access Circuits, Electrical Wiring17-18 Excursion

19 Expedition20 Tire Pressure Awareness Label21 Truck Body Builders Advisory Service Website22 Obtaining Publications

• Ford Truck Body Builders Layout Book• Incomplete Vehicle Manual• Ford Recreation Vehicle and Trailer Towing Guide• Service Publications (i.e. Wiring Diagrams, Shop Manuals)• Body Builder Quality Bulletins

23 Important Phone Numbers and Web Sites

1

Body Builder Quality ProgramsThe following organizations are established to provide technical assistance to vehicle modifiers of Ford Truckchassis. They are part of the Special Vehicle Engineering Department within the Ford North American TruckConsumer Business Group.

• TRUCK BODY BUILDER ADVISORY SERVICEProvides daily technical assistance for truck body builders.Phone: 877-840-4338Fax: 313-594-2633Web Site: www.fleet.ford.com/truckbbasE-Mail: bbasqa@ford.comF-Super Duty Class “A” Chassis Motorhome Liaison: 313-337-6520 Fax: 313-621-8032

• MODIFIED VEHICLE ENGINEERING & QUALITY PROGRAMSResponsible for qualifying the engineering process control capability of final stage manufacturers underthese programs:

– QVM-Ambulance Quality Program– QVM-Motor Home & Transit Bus Quality Program– Conversion Van Quality Program– F-Series Quality Program– Adaptive Mobility Quality Program

• MVE SHIP-THRU SECTIONResponsible for qualifying the engineering process control capability of companies that up-fit vehicles inthe ship-thru process.

Assembly Plant Job #1 Timing2002 Model

Vehicles Assembly Plant Job #1

F-150 Regular and SuperCab Norfolk Assembly Plant 7/30/01Kansas City 8/20/01Ontario Truck Plant 8/27/01

F-150 SuperCrew Kansas City 8/20/01

Super Duty F-SeriesF-350/450/550 Chassis CabAnd Pickup Box Delete: Kentucky Truck Plant 7/16/01F-250/350 Pickup: Kentucky Truck Plant 7/16/01F-250/350 Pickup: Cuautitlan, Mexico 8/13/01

F-650/750: Cuautitlan, Mexico 8/27/01

F-53 Class A Motor Home Chassis15,700, 18,000, 20,500-lb. GVWR: Detroit Chassis Plant 7/26/0122,000lb. GVWR: Detroit Chassis Plant 7/26/01

Excursion Kentucky Truck Plant 7/16/01

Expedition Michigan Truck Plant 7/23/01

E-Series (except E-550) Lorain Assembly Plant 7/23/01E-550 Super Duty Cutaway Lorain Assembly Plant 1st Quarter 2002

2

F-1502002 MAJOR PRODUCT FEATURE CHANGES

■ MODEL/TRIM:• New King Ranch trim package available on SuperCab.• Harley Davidson F-150 features 5.4L Supercharged 2V engine. “Supercharged”

added to fender/tailgate badges; revised grille (larger quasi-billet chrome bars withlarger spacing between bars), and flame accents added to the exterior upper tapestripe and interior front and rear console covers (Job #1 1/7/02)

• New FX4 Off-Road Equipment Group features 17" 5-Spoke Cast AluminumWheels, “FX4 Off-Road” decal, skid plates and white colored branded Ranchoshock absorbers. Also includes color-keyed grille insert, wheel lip moldings andfront bumper top cap (Dark Shadow Gray with XLT and Arizona Beige or Silverwith Lariat). Matching lower two-tone and unique paint break stripe is optional.

■ POWERTRAIN/CHASSIS:GVWR/GCWR• 6,050 lbs. GVWR replaces the 5,600 lbs. GVWR (Regular Cab) and the 6,000 lbs.

GVWR (SuperCab) as standard with 4.2L engine (Optional 6,000 lbs. GVWRPayload Package No. 2 available last year on Regular Cab is also cancelled).

• 7700 Payload Group renamed 7700 Lb. Payload Group A (7,700 lbs. GVWR/3.73axle/13,500 lbs. GCWR/8,800 lbs. max. trailer weight). New 7700 Lb. Plus PayloadGroup B is available on 139" wheelbase Regular Cab and Supercab 4x2 modelsonly and includes Group A content plus upgraded 22-plate auxiliary transmissionoil cooler, Class III Trailer Tow Group and 4.10 limited slip axle (7,700 lbs.GVWR/4.10 axle/15,000 lbs. GCWR/8,800 lbs. max. trailer weight).

Engine• Heavy Duty Electrical/Cooling Group cancelled. 72 amp.-hr. battery and auxiliary

automatic transmission oil cooler (number of plates varies by application) areincluded with Class III Trailer Tow Group and 7700 Lb. Payload Groups A and B.The 7700 Lb. Payload Groups also include an upgraded radiator with 1.42" corethickness.

• 4.6L engine includes new integrated air fuel module (IAFM), to include air cleanerassembly, air filter, mass air flow sensor and AIT sensor to meet 2002 emissionsrequirements.

• 6 rib serpentine belt replaces 8 rib belt/pulley (except Lightning and HarleyDavidson).

Tires/Wheels• New spare tire lock is standard (late availability).

■ EXTERIOR:Paint and Trim• Colors added are Dark Shadow Grey and True Blue. Color availability expanded

are Estate Green available on XLT and Lariat and Toreador Red available onLariat. Colors deleted are Wedgewood Blue and Island Blue.

■ INTERIOR:Comfort and Convenience• Interior revisions to meet FMVSS 201Occupant Protection in Interior Impact: New

windshield header assembly and A-pillar inner (similar as 2002 Expedition); Newgrab handles (added foam); New headliner assembly (added foam), coat hooks,sun visor attaching brackets and safety belt with adjustable D-ring; New side rails,

front and rear door and rear quarter trim (adding ribbing and cartridges toenhance occupant protection (Job #1 1/2/02).

• Air Conditioning is standard with XL trim (optional with Work Truck Group).• New electronic automatic temperature control air conditioning is standard on

SuperCrew Lariat and King Ranch models (late availability on SuperCab).• New “Fuel Cap Loose” warning light.

F-1502002 MAJOR PRODUCT FEATURE CHANGES (continued)

3

4

F-250/350/450/550 Super Duty2002 MAJOR PRODUCT FEATURE CHANGES

■ MODEL/TRIM:• New F-450-550 SuperCab DRW 161.8" WB/60" Cab-to-Axle (CA) Chassis Cab

models.With the availability of SuperCab on F-450 and F-550, this popular cabconfiguration is available on all F-Series from F-250 to F-750.

- Back seats can accommodate 3 passengers- Also suitable for stowage of tools or cargo

• Pickup box delete option is now available on long wheelbase (8-foot box) F-350SRW models.

■ POWERTRAIN/CHASSIS:GVWR/GCWR• Conventional towing ratings increased to a maximum of 12,500 lbs. (from 10,000

lbs.) with 6.8L V-10 (4.30 axle) and 7.3L Diesel engines (late 2001 MY change).• Maximum GVWR increased to 12,500-lbs. (from 11,500-lbs.) on 49-states F-350

DRW Pickup models with 7.3L Diesel engine (172.4” WB Crew Cab remains at11,500-lbs. GVWR; California remains at 11,000-lbs. GVWR). Conventional trailertow ratings increased to a maximum 23,000-lbs. GCWR/13,500-lbs. trailer weight(from 20,000-lbs. GCWR/12,500-lbs. max. trailer weight) on F-350 DRW Pickupmodels with 6.8L V-10 (4.30 axle) and 7.3L Diesel (4.10 axle) (EffectiveDecember, 2001).

Axles• Synthetic oil lubrication included with all 30,000-lb. GCWR option packages (all

other applications include mineral oil lubrication).Engine• 6.8L Bi-fuel (Gas/LPG) Vehicle Program is canceled.• G05 Hybrid/OA long life coolant (100K miles) standard for all applications.Electrical• 6G 130 ampere/1950 watt alternator standard for all engines. Dual 130 ampere/

1950 watt alternators optional with 7.3L diesel engine.• 7/4 pin trailer towing connector revised to 7 pin connector.• New interior power distribution junction box combines the power distribution box

with the junction box and places all fuses under the instrument panel.Fuel• Dual Fuel Tank option (19-gal. midship/40-gal. aft-of-rear axle) is available on

DRW Chassis Cabs with 7.3L V-8 Diesel. Includes new instrument panelmounted tank selector control switch.Greater fuel capacity means increased range —fewer stops. That’s the ideabehind the new dual fuel tank option. A tank selector control switch is convenientlymounted on the instrument panel.

Transmission• ZF-650OD 6-speed manual overdrive transmission replaces the 5-speed manual

overdrive transmission as standard with 5.4L V-8 and 6.8L V-10 engines.Suspension• Auxiliary rear springs are now standard on all models (Late 2001 MY change)Tires• New 225/70R19.5F traction tire is available on 4x2/4x4 in the Traction Package or

on 4x4 in the Max Traction Package on F-450-550 models. 225/70R19.5F all-terrain tire will be phased out in January, 2002.

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■ EXTERIOR:Lighting• New “jeweled” single beam complex reflector headlamp with separate park and

turn lamps are standard with XLT, Lariat and Lariat LE.Mirrors• Trailer tow mirrors include new forward fold feature.

The popular manual telescoping/power glass trailer tow mirrors now fold bothforward and backward.

Paint and Trim• Colors added are Arizona Beige and Dark Shadow Grey. Colors deleted are

Harvest Gold and Bright Amber.• Two new exterior color schemes for Lariat LE include Ebony monotone exterior or

Ebony/Dark Shadow Gray/Ebony two-tone exterior.• Three new two-tone tape break stripes/color combinations.

■ INTERIOR:Comfort and Convenience• New roof/headliner mounted ride handle for the front seat outboard passenger is

standard for all cab styles. Crew Cab also includes standard L.H./R.H. ridehandles for rear seat outboard passenger seating positions (Handles are same asExcursion).

• XLT cloth sun visors with L.H. map strap and R.H. uncovered mirror madestandard on XL models.

• New larger Lariat overhead console includes sun glasses bin, garage door openerbin and trip computer with distance-to-empty (deleted with dual fuel tanks),outside temperature and compass displays (Similar to F-150 console).The new, larger Lariat Overhead Console extends this popular feature to the F-250 through F-550 range, adding even more storage convenience.

• SuperCab rear door trim panels are revised to include new standard L.H./R.H.cup holders for 12-oz. cans and 20-oz. bottles.SuperCab rear seat passengers can now enjoy the convenience of a cup holder,integrated into the rear door trim panel on both right hand and left hand sides.

• New Security Lock Group is optional on XLT and standard on Lariat and Lariat LEand includes Remote Keyless Entry and new Auto Lamp and Auto Lock/Relockfeatures.

Instrumentation• Transmission fluid temperature gauge replaces battery gauge with automatic

transmission applications (Battery warning light remains).The transmission fluid temperature gauge allows the driver to monitor fluidtemperature and alter usage conditions accordingly.

Seating• New XL cloth seat trim materials are “Hopsack” side facings/bolsters with “Links”

inserts (replaces Fargo/Summit cloth, sew style carryover).• New sew styles and foam for XLT, Lariat and Lariat LE Regular Cab and Crew

Cab seats for comfort and appearance. New XLT cloth seat trim materials are‘Elliott” side facings/bolsters with “Bazaar” inserts (replaces Beacon/Dillon cloth).

• Inboard arm rests added to front and rear Captain’s Chairs.• Crew Cab 6-way power adjustable front outboard passenger seat is optional on

XLT and standard on Lariat and Lariat LE.

F-250/350/450/550 Super Duty2002 MAJOR PRODUCT FEATURE CHANGES (continued)

6

ELECTRICAL WIRINGPOWER TAKE-OFF CIRCUIT INSTALLATION

The Body Builder must provide a PTO Circuit to alert the PCM to PTO operation. Failure to provide this circuitmay result in erroneous emission codes, and inadvertent illumination of the “Service Engine Soon” light duringPTO operation.

Circuits 294 (WH-LB) is located in the center of the instrument panel, labeled “Power Take-Off Circuit” and thecircuit 322 (LB-Y) is located to the right of the parking brake labeled “Customer Pass-Thru/PTO and CTOCircuits” (see Figure A). They are near the customer pass-thru circuits, and are blunt-cut with shrink wraptubing over the cut ends. They are easier to access from the front of the instrument panel (IP) by removingthe access panel below the steering column (4 quarter-turn fasteners).

Splice circuit 294 (WH/LB) to the body builder provided wire that connects to the positive side of the PTOindicator switch or PTO control relay. Splice circuit 322 (LB-Y) to the body builder provided wire that connectsto the positive (switched) side of the PTO indicator light. (See Figure C1). In electrically-actuated PTOsystems, must be relay isolated from the circuit containing the solenoid or PCM DAMAGE COULD RESULT(See Figure C2).

FIGURE A - VIEW UNDER DASH — SUPER DUTY F-SERIES

FIGURE C1 - SUPER DUTY F-SERIES FIGURE C2 - SUPER DUTY F-SERIES

7

Trailer Tow Second Unit Body Wiring Tap Schematic – Super Duty F-Series

For the 2002 Model Year, Super Duty F-Series (F-250/350/450/550) vehicles have had extensive electricalchanges. All fuse numbering has changed with the combination of the Power Distribution Box and theJunction Box into the Power Distribution Junction Box (PDJB). The PDJB is found under the dash, below thesteering wheel and behind the modesty panel. Another change has been the addition of relays to Trailer TowStop/Turn Circuits 52 (Yellow) and 64 (Dark Green). This change will require SUB installers, who have usedthe trailer tow connector to connect their SUB, to rethink their connection. The relay isolation of circuits 52and 64 require the connection of some load to the Ford Stop/Turn connectors or the turn signals will flash asif a bulb were burned out. Either connect your SUB Stop/Turn signals to the Ford Stop/Turn signal connectorsor connect a resistive load to each of the connects.

Power Distribution Junction Box

8

Electrical Wiring Schematic for Adding Lights or Electrical Devices

Changes To Circuits

Check your fuses and circuits for the 2002 Model Year. DO NOT ASSUME that there are no changes for the2002 Model Year F-250/350/450/550 vehicles. The DRL control circuits are new for 2002. The elimination ofthe GEM has also brought about many electrical changes. Check your circuits and your fuse numbers and ifyou have questions call the Ford Truck Body Builders Advisory Service at (877) 840-4338 or E-mail us atbbasqa@ford.com. Contact us before applying power to any circuit you are unsure about. This may take moretime now, but it will save you from damaging the Ford vehicle’s electrical system. Take the time to contact usand you will save more than time.

9

F-650 Super Duty2002 MAJOR PRODUCT FEATURE CHANGES

■ MODEL/TRIM:• Lo-Profile Package (July 2001 Introduction)

– 8.5" frame– 19.5" 8-hole disc wheels– 245/70R 19.5G tires

- G159 front- G124 rear

– Tuned springs and shocks– Improved braking for lighter GVW’s

• Rescue Package (available December, 2001)– Lo-Profile 20,000 lb. GVWR– 108" CA– HAS 120 single axle air suspension with dump valve – Hendrickson system

Dump valve provides “kneeling” feature– 225 hp Cummins engine with Allison 2400 5-speed automatic transmission– 270 amp alternator– Hydraulic brakes– 18K GVWR available

■ POWERTRAIN/CHASSIS:GVWR/GCWREngine• 6 rib serpentine belt replaces 8 rib belt/pulley.• Caterpillar 3126 Low Emission Vehicle (LEV) available• Allison AT545 automatic transmission now standard w/Cummins 210 HP/520 lbs.-

ft. torque• Aluminum wheels (Lo-Pro) available as stand-alone option

■ EXTERIOR:Paint and Trim• Chrome grille and chrome headlight bezels available as a stand-alone option• Telescoping mirrors available

■ INTERIOR:Trim• Medium Flint interior replaces Medium Graphite

10

F-750 Super Duty2002 MAJOR PRODUCT FEATURE CHANGES

■ MODEL/TRIM:• New F-750 tractor package. Targeted at the beverage industry and single axle

tractor applications – 158" WB Regular Cab– 179" WB SuperCab.– Available with Caterpillar and Cummins diesel engines, and MD Automatic

transmission

■ POWERTRAIN/CHASSIS:GVWR/GCWR• 30,000 lb. GVWR

- Allison AT545 Automatic transmission is now standard with Cummins210hp/520 lb.ft. torque. This replaces the manual transmission as standard.

• 33,000 lb. GVWR- Allison MD-3060CR automatic transmission now standard with Caterpillar

210 hp/605 lb. ft. torque. This replaces the manual transmission as standard.Engine• 6 rib serpentine belt replaces 8 rib belt/pulley• Caterpillar 3126 Low-Emission Vehicle (LEV) available

EXTERIOR:Paint and Trim• Chrome grille and chrome headlight bezels available• Telescoping mirrors available

INTERIOR:Trim• Medium Flint interior replaces Medium Graphite• Tilt wheel available on 33K GVWR

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■ MODEL/TRIM:• Front GAWR increased to 7,500 lbs.• Rear GAWR increased to 14,500 lbs.• Shocks and springs retuned to match higher GAWR

■ POWERTRAIN/CHASSIS:GVWR/GCWR• 22,000 lb. GVWR and 4-Wheel/4-Channel ABS• Visual differences between 20,500 lb. vs. 22,000 lb. GVWR —

22,000 lb. GVWR has:– Tape Tag on axle tube with P/N – white and blue lettering– Paint dot on rear of axle housing– Springs have P/N painted in green on top leaf– Bar coded incomplete vehicle label has GVWR listed on it

Engine• 6 rib serpentine belt replaces 8 rib belt/pulley

F-53 Class A Motorhome Chassis 2002 MAJOR PRODUCT FEATURE CHANGES

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MODEL/TRIM:Standard Features Include:• Tilt Steering Wheel• Speed Control (Standard on Recreational Vans/Optional on

Commercial Vans)• Back Lit Switches• Rear Chrome Step Bumper (Contour Chrome Bumper - Optional)• Rear Vinyl Floor Covering (Maslite) w/delete option

POWERTRAIN/CHASSIS:Rear Axle• New 4.56 Limited Slip (LS) Axle (5.4L NGV, 6.8L) - E-450 Cutaway• New 4.10 Limited Slip (LS) Axle (7.3L Diesel) - E-450 CutawayEngine• New Fuel Pump - Turbine Type Pump (Replaces Rotor)• AC Scroll Compressor

New AC Scroll Compressor helps increase durability. Location hasnot changed, but plumbing connections are all-new for 2002.

• New Aluminum Aux. Heat & A/C Tubes Lines• New Dual Idler Bearings (FEAD) - 7.3L Diesel

New Dual Idler Bearings help improve high mileage life• Improved Belt Life & Noise on All Engines (Orion Material)• New Engine Oil Cooler - 6.8L• New Nickel Plated Spark Plug Shell• New Stainless Steel Engine Cup Plug• Improved NVH - 4.6L, 5.4L, 6.8L - Valley Stuffer• New Anti Splash Baffle in Master CylinderFrame• New E-Coating on Frames (Replaces Wax Coat/Paint)Suspension• New Upper Ball Joint Wear - Added Grease Plugs.• New Lower Front Shock Bushing Material (Urethane)

EXTERIOR:Mirrors• New Exterior Mirrors (First Quarter, 2002)

Cutaway features Standard Trailer Tow Mirror similar to the onefeatured on F-Series. The E-Series Van with Trailer Tow Option willalso receive a new base mirror at mid-model year.

Paint and Trim• New Wheel Covers Wire Diameter & Dimension Controls• New Caliper Shield (Stone Pecking) (E-350, E-450 Only)• Sound Deadening and Sealing• Thicker Spray on PVC in Wheel Wells• Extensive Body Sealing• New Front Door Hinge Bushings (Sprayed Teflon vs. Bonded)• Running Boards Optional on Vans and Cutaways

E-Series Van / Cutaway / Stripped Chassis2002 MAJOR PRODUCT FEATURE CHANGES

New Telescopic Mirror (Cutaway)

New Base Mirror (Van)

New AC Scroll Compressor

New Brake Caliper Shield

3 Dome Lights (Standard)

13

INTERIOR:Comfort and Convenience• New Illuminated Rear Aux. Heat & A/C Switch• New CD6 Player - Optional w/Dual Media• New Dome Light On/Off Switch (Rear Door) and 3

Lamps Standard• Diesel Engine Cover (4.2L, All E-Traveler & 7.3L Diesel)• Dash Panel Sound Absorber Front• Carpet - Added Binder and Upgraded Padding• Wheel House Covers Added• Rear Vinyl Floor Covering (Maslite) - Upgraded padding.• New Dash Cowl Reinforcement—Stiffer I/P cross car

beam.• Grab Handle - A-pillar/passenger side.• Floor Covering, front & rear (Std.)• Under Seat Storage - passenger side• Armrest - inboard, all front seatsDoor Trim• New front door trim panels (Late Availability)Instrumentation• New Low Fuel Warning Light - I/P Cluster.• New Speed Control “On” Indicator Light - I/P Cluster.Seating• New Seat Material - Improved vinyl (Stockton 2

Directional).• New Seat Material - Increased foam density.• New Seat Material - Increase flex mat wire gage/added

hook.

INTERIOR – Comfort and Convenience (continued):

E-Series Van / Cutaway / Stripped Chassis2002 MAJOR PRODUCT FEATURE CHANGES (continued)

New Front Door Trim Panels

New Valley Stuffer improves NVH

New Instrument Panel Reinforcement

OLD NEW

New DualIdler Bearingsreplaceformer bear-ings forimproved highmileage life

Instrument Panel Sound Absorber (NVH)

14

E-550 Cutaway (late availability)2002 MAJOR PRODUCT FEATURES

MODEL/TRIM:• Five wheelbase lengths: 159.5", 177.5", 191.5", 209.5", 233.5"

Five wheelbase lengths means E-550 will be the vehicle of choicefor a greater range of commercial applications.

POWERTRAIN/CHASSIS:GVWR/GCWR• 17,500 lbs. and 19,000 lbs. GVWR availability.• 20,000 lbs. max. GCWR

The new 17,500 and 19,000 lbs. GVWR allows E-550 toaccommodate larger payloads.

GAWR• 6,000 lbs. front; 11,500 lbs. or 13,500 lbs. rear.Engine• 6.8L V10 gas or 7.3L diesel engine. (Diesel 49 states only).Fuel Tanks• 55 gallons Aft-of-axle (Standard)Tires/Wheels• 19.5 in. wheels and tires• Steel wheels (Standard)• Polished aluminum wheels (Optional)Transmission• 4-Speed electronic automatic with overdrive (4R100)ManeuverabilityReduced turning diameter vs. E-350/E-450

Tighter turning diameter makes E-550 a perfect vehicle for movingabout city streets for local pick up and delivery.

EXTERIOR:Lighting• Roof marker lights (Optional)Mirrors• New trailer tow mirrors (Standard); Mirror Delete Option available

New standard manually-telescoping trailer tow mirrors featureelectrically adjusted glass and are perfect for 96"-wide second-unitbodies.

Trim• Running boards (Standard)

Standard running boards make ingress and egress easier.• Wheel lips (Standard)• New grille and lower bumper fascia

Distinctive new Super Duty grille and lower bumper fascia add tothe overall good looks of E-550

Telescopic Mirror

Running Boards (Std.)

Wheel Lips (Std.)

Distinctive Grille and Lower Bumper Fascia

Roof marker Lights (Optional)

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Interior:Comfort and Convenience• Front Door Trim Panel

Front door trim with convenient storagepocket

• Premium Plus CD6 Radio (Optional)• Tilt Wheel (Standard)• Dual Media Radio

Provides in-dash single CD player andcassette

• Speed Control (Optional)

Functional:Frame• Hour-glass design with common frame

section around rear axleCommon frame section with hour-glassshape and flat frame design to facilitateease of body installation.

• Multi-piece Construction• Flat Frame Design• Stiffer frame (than E-450)• Removable engine crossmember for

servicing front engine oil panFront Axle/Suspension• Solid forged I-beam front axle• Tapered leaf springs• Gas shocks with 35 mm bore and 580 mm

extended length • 36 mm diameter torque bar Steering• Haltenberger type steering geometry• Steering gear, heavy duty-high output• Wheel cut angle, 40 degreesRear Axle/Suspension• Axle, Dana 135 Medium Duty (13,500 lbs.

capacity)• Tapered leaf springs (11,500 lbs. standard,

13,500 lbs. optional)• Gas shocks with 35 mm bore and 703 mm

extended length• 31 mm diameter torque bar

E-550 Cutaway (late availability)2002 MAJOR PRODUCT FEATURES (continued)

Flat Frame Design

Front Suspension

Stiffer Frame

Crossmember

Common frame section & hour-glassshape

New Front Door Trim Panels

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Electrical WiringCUSTOMER ACCESS CIRCUITS

This chart contains the changes and additions to the Customer Accessible Circuits for 2002 E-Seriesvehicles. Changes to other circuits may have occurred in circuits not designated as Customer Access Circuits.For this information refer to the 2002 Ford E-Series Wiring Diagrams Book available from Helm, Inc.(800) 782-4356 or www.helminc.com.

Circuit Color Wire Functional DescriptionNumber Code Gauge

2 WH/LB 18 Right turn signal3 LG/WH 18 Left turn signal14 BR 18 Marker lamp feed to electric brake controller22 LB/BK 12 Trailer brake controller or B + feed43 DB 12 Electric trailer brake controller49 O 12 Relay feed ignition run52 Y 16 Fused left hand stop/turn53 BK/LB 18 Courtesy lamps59 LG/YE 18 Courtesy switch feed64 DG 16 Fused right hand stop/turn206 W 16 Ground511 LG 18 Center high mount or lamp feed stop648 WH-PK 18 Clean tach output (CTO)867 DB 12 Customer pass-thru circuits868 GY/R 12 Customer pass-thru circuits962 BR-W 16 Relay feed marker lamps963 BK-LG 16 Relay feed backup lamp

CIRCUIT CHART

THE “CHMSL” ELECTRICAL CONNECTION FOR ASTRIPPED CHASSIS IS PROVIDED IN A DETAILEDSCHEMATIC, WHICH IS PACKAGED WITH THE BODYBUILDER ELECTRICAL CONNECTORS

FRONT OF VEHICLE

TO INSTALL “CHMSL”, UNWRAP TAPE FROM HARNESSIN THIS AREA AND REMOVE JUMPER CONNECTION TOEXPOSE THE “CHMSL CONNECTOR”

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Excursion2002 MAJOR PRODUCT FEATURE CHANGES

MODEL/TRIM:• New exterior colors: True Blue (replaces Deep Wedgewood Blue), Aspen Green

(replaces Dark Satin Green), Medium Wedgewood Blue - XLT only (replacesMedium Steel Blue), Mineral Gray - Limited only (replaces Arizona Beige), SilverBirch - XLT only (replaces Silver).

• Revised Fleet Special Service Package – Power heated, sail mounted exterior mirrors– Seat configuration changes

• Deleted optional Limited Feature Vehicle (No Boundaries Package)

POWERTRAIN/CHASSIS:Engine• New G05 Hybrid/OA long life (100K mile) engine coolantElectrical• 130 amp./1950 watt 6G alternator w/central load dump capability (CLD) now

standard on gas engines, replacing HD alternator • Heavy Duty Trailer Tow Package revised to eliminate 7/4 way adapter• New interior power distribution junction box combines the power distribution box

with the junction box and places all fuses under the instrument panel

EXTERIOR:Lighting• Single beam jeweled headlamps replace aero halogen headlamps.• Modified position and parking light assembly.Mirrors• Fold forward feature added to optional Telescoping Trailer Tow Exterior MirrorsPaint and Trim• Deleted Chestnut exterior color• Medium Platinum XLT bodyside cladding replaces Medium Flint• Chrome insert added to Limited bodyside cladding• New Paint Stripe Colors: Mocha (replaces Saddle), Medium Dark Charcoal

(replaces Blue) Windshield Wipers• New ‘smart” windshield wiper motors (front and rear)

INTERIOR:Comfort and Convenience• Medium Flint interior color replaces Medium Graphite (XLT only) • Revised Comfort Group • Revised Convenience Group • 12 oz. Lanier carpet replaces 12 oz. Midway• 12 oz. Lanier floor mats replace 12 oz. Midway on XLT.• Fixed accelerator and brake pedals now standard on XLT • Standard auto door locks • Integrated DVD System replaces Video Cassette Player in Rear Entertainment

System (Late Availability)• Rear Seat Entertainment System now optional on XLT

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Instrumentation• Standard Electronic Automatic Temperature Control (EATC) on Limited.• US Hybrid III Instrument Cluster replaces US Instrument Cluster • Deleted Mini-overhead console • New optional Ultimate Group on LimitedSeating• New seat sew styles • Elliott cloth bolster seat material replaces Beacon • Nudo leather replaces “sheared” nudo leather on Limited • New optional 2nd row bucket seats on Limited• Extended lumbar added to all 1st row captains chairs and 40/20/40 bench seats• Inboard arm rests on captains chairs have increased length

Excursion2002 MAJOR PRODUCT FEATURE CHANGES (continued)

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Expedition2002 MAJOR PRODUCT FEATURE CHANGES

MODEL/TRIM:Revised Eddie Bauer Premier Package.

POWERTRAIN/CHASSIS:Axles• 3.55 rear axle ratio replaces 3.31 on 4x2 w/4.6L engine.• 3.73 rear axle ratio high altitude restriction removed on 4x4 w/5.4L engine.Engine• 6-rib serpentine belt replaces 8-rib belt/pulley.• Added cylinder block ribbing to 5.4L engine for NVH improvement.• New G05 Hybrid/OA long life (100K mile) engine coolant.• Wisconsin added to list of U.S. States (7 total) requiring engine block heater.

Available through FCSD in other states.Steering• Assist power steering replaces variable assist.

EXTERIOR:Paint and Trim• Deleted exterior colors: Dark Highland Green, Dark Toreador Red, Deep

Wedgewood Blue, Estate Green.

INTERIOR:Seating• Optional Rear Seat Entertainment System on both XLT & Eddie Bauer.

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Tire Pressure Awareness Label

Ford Motor Company is equipping all E-Series and F-Super Duty models with a Tire Pressure Awarenesslabel that will be located inside the fuel door. For incomplete vehicles without fuel doors, the label will beplaced in the incomplete vehicle package. The label is to be installed by the Final Stage Manufacturer in anoticeable location near the fuel tank fill location. This label contains tire size and front/rear pressures. Thelabel must be applied to a clean surface.

E-350

E-450

Incomplete Vehicle

F-Series

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Truck Body Builders Advisory ServiceWebsite

Hot Off The Press: Displays latest up-to-date publications available to BodyBuilders

Truck Support Contacts: Displays frequently requested phone and fax numbersThese may be useful in answering your truck-related ques-tions.

Body Builder’s Layout Book: Provides access to and order capability for Body BuilderLayout Book

Bulletins: Displays the latest Bulletins relative to CVQP, QVM andMVE programs

(http://www.fleet.ford.com/truckbbas)

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OBTAINING PUBLICATIONSFord Truck Body Builders Layout BookOrder and access via www.fleet.ford.com/truckbbas.

Incomplete Vehicle Manual Access at www.fleet.ford.com/truckbbas.

Ford Recreation Vehicle and Trailer Towing GuideThe guide covers cars and light trucks, and includes trailer and camper weight ratings and the list of vehiclessuitable for flat-towing. A copy can be obtained by contacting the Ford RV Information Service at (800) 245-7343, leave name and shipping address, or Fax to (248) 936-3300.

Service PublicationsThe “Ford Technical Publications Catalog” list the service publications available, and includes pricing, an orderform, and a mailer. Contact Helm, Inc. at 800-782-4356.Useful publications include “Truck Wiring Diagrams” and the “Service Specifications” book.

Body Builder Quality BulletinsBody Builder Quality Bulletins provide key information to assist Body Builders in interfacing with a Fordchassis:• Conversion Van Quality Program (CVQP) Bulletins• Qualified Vehicle Modifier (QVM) Bulletins• Modified Vehicle Engineering (MVE) BulletinsThese bulletins can be accessed via the web at www.fleet.ford.com/truckbbas.

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IMPORTANT PHONE NUMBERS AND WEB SITES

INTENDED FOR GENERAL USERS & CUSTOMERS OF COMPLETED VEHICLES

Ford Customer Assistance Customer Assistance Center: 800-392-3673Roadside Assistance Center: 800-241-3673

Web Site: www.ford.com

Ford RV (Customer Assistance Center)To locate the nearest RV service center: 800-444-3311

INTENDED FOR FINAL STAGE MANUFACTURERS & VEHICLE MODIFIERS

Ford Truck Body Builders Advisory Services (BBAS) Truck: 877-840-4338Fax: 313-594-2633Web Site: www.fleet.ford.com/truckbbasE-Mail Address: bbasqa@ford.com

List of Ford Pool Accounts and Qualified Vehicle Modifiers www.fleet.ford.com/truckbbasClick on “Specialty vehicles” on the navigation bar and select the desired vehicle type.

F-Super Duty Class A Motorhome Chassis Liaison313-337-6520Fax: 313-621-8032

Ford Alternative Fuels InformationVehicle models available, list of authorized Ford dealers, and Leaf & Road Newsletter.

877-ALT-FUEL(877-258-3835)

Ford Component Sales734-523-5702Fax: 734-523-5917

E-Series Aft-of-Axle Fuel Tank Kit (gasoline and diesel)TDM, Inc.: 800-540-3913Alternate: 734-458-9100Fax: 734-458-9118

Dealer Special Order, DSO Fleet Sales 1-800-34-FLEETSelect #4

SVED-09-01 August, 2001 AOC 16126 Litho in USA

Information herein was correct when approved for printing. Ford Motor Company reserves the right todiscontinue or change at any time, specifications, designs or programs without incurring obligation.

North American TruckSpecial Vehicle Engineering Department