2008 E-Series (Technical Data Only)

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87002 May,

PRELIMINARYPRELIMINARY

TECHNICAL TECHNICAL DATA ONLYDATA ONLY

E-SERIES

IMPORTANT NOTICE

The specifications and designs describedherein are believed to be correct as of thetime that this book was approved forprinting, but accuracy cannot beguaranteed. They are intended only toprovide basic data regarding such mattersas dimensions and weight ratings of Ford-built chassis. The information contained inthis book is general and nothing containedherein is to be regarded as providingspecific or comprehensive instructions forthe completion of a particular vehicle or asauthorization by Ford of the specificmodifications, alteration or designs ofindividual vehicles.

Regulations such as those issued by theFederal Highway Administration (FHWA)or issued pursuant to the OccupationalSafety and Health Act (OSHA), and/orstate, provincial, and local laws andregulations may require installation ofadditional equipment for the particular useintended for the vehicle. It is theresponsibility of the subsequent stagemanufacturer or completed vehicle altererand the vehicle purchaser to ascertainhow the vehicle will ultimately be used, ifFHA, OSHA or state provincial or localregulations apply and how the vehicle ascompleted will comply with thoserequirements.

Representations regarding the complianceof any Ford-manufactured incompletevehicle to any rule, regulation or standardissued pursuant to the National Traffic andMotor Vehicle Safety Act or the CanadianMotor Vehicle Safety Act are set forth onlyin the incomplete vehicle manual whichaccompanies each incomplete vehicle.Ford reserves the right to discontinuemodels or change specifications ordesigns at any time without notice andwithout incurring any obligation.

Nothing contained herein is to beconstrued as a representation that suchequipment required for the particular useintended has been installed on thecompleted or incomplete vehicle.

REFERENCE INFORMATION

FORD TRUCK BODY BUILDERS LAYOUT BOOK

FORD TRUCK BODY BUILDER ADVISORY SERVICE

The Body Builders Layout Book can beaccessed via the web atwww.fleet.ford.com/truckbbas/ under the“Publication” tab. A CD-ROM copy may beobtained by contacting the Body BuildersAdvisory Service.

FORD SERVICE PUBLICATIONSMany Ford Service Publications pertain toa specific Model Year and vehicle types.The following publications are a few ofmany manuals which are available fromHelm Incorporated; call 1-800-782-4356or contact Helm, Inc. at their website:www.helminc.com• Ford Truck Shop Manuals• Ford Towing Manuals• Ford Wiring Diagrams• Ford Truck Shop Manuals and Wiring

Diagrams on CD-ROM

The Ford Truck Body Builder AdvisoryService assistance may be consultedregarding information contained in thismanual. For assistance:• Call toll free (877) 840-4338• Fax (313) 594-2633• E-Mail [email protected] or at the

BBAS website - www.fleet.ford.com/truckbbas/

Include your name, company andtelephone number with all inquiries. Ifrequesting written materials, include yourmailing address.

For the most recent information and updates to this publication refer to www.fleet.ford.com/truckbbas.

© 2007 Ford Motor Company

E-Series Wagon Model Lineup ............................................................................................ 1

Dimensional Data – Wagon

E-150/E-350 Super Duty 7-Passenger – Quad Captain’s Chairs/3-Passenger Bench ... 2-3

E-150/E-350 Super Duty – 8/12-Passenger.................................................................... 4-5

E-350 Super Duty Extended – 11/15-Passenger ............................................................ 6-7

E-Series Van Model Lineup.................................................................................................. 8

Dimensional Data – Van

E-150/250/350 Super Duty ............................................................................................. 9-10

E-150/250/350 Super Duty Crew – Regular / Extended Length ..................................... 11-12

Axle / Tire / Vehicle Height Data E-Series

Wagon / Van................................................................................................................... 13

Incomplete E-150/250/350 Super Duty Recreational Van.................................................... 14

E-Series Fuel System Evaporative Emissions ..................................................................... 15

E-Series Super Duty Cutaway / Stripped Chassis Model Lineup......................................... 16

Dimensional Data – Super Duty Cutaway

E-250/350 – 138" Wheelbase (SRW)............................................................................. 17

E-350 – 138" Wheelbase (SRW/DRW) .......................................................................... 18-19

E-350/450 – 158" Wheelbase (DRW)............................................................................. 20-21

E-350/450 – 176" Wheelbase (DRW)............................................................................. 22-23

Dimensional Data – Super Duty Stripped Chassis

E-350 – 138" Wheelbase (SRW/DRW) .......................................................................... 24

E-350 – 158" Wheelbase (DRW).................................................................................... 25

E-350/450 – 176" Wheelbase (DRW)............................................................................. 26

Axle / Tire / Wheelhouse / Vehicle Height Data E-Series Super Duty

Cutaway / Stripped Chassis ........................................................................................... 27-28

Ground Clearance Data Super Duty Cutaway / Stripped Chassis ....................................... 29

Battery Box Locations E-350/450 Dual and Gas Auxiliary .................................................. 30Fuel Filler System E-Series Super Duty Cutaway / Stripped Chassis ................................. 31

Aft-of Axle Fuel Tank E-350/450 Super Duty Cutaway / Stripped Chassis .......................... 32

Fuel System Evaporative Emissions E-Series Super Duty

Cutaway / Stripped Chassis ............................................................................................ 33

Back of Cutaway Cab – Profile Dimensions E-250/350/450 Super Duty Cutaway

Body “Section A” ............................................................................................................. 34

Seat Position E-250/350/450 Super Duty Cutaway.............................................................. 35

Sear Track Travel / H-Point Location E-Series ..................................................................... 36

Power Take-Off (PTO) Applications Wiring Locations .......................................................... 37

Electrical Wiring Customer Assess Circuits......................................................................... 38-39

E-Series Trailer Tow Wiring.................................................................................................. 40-41

E-Series Trailer Lamp Plug and Wiring................................................................................ 42-43

Second Unit Body Mounting E-Series Cutaway................................................................... 44

Second Unit Body Mounting E-Series Stripped Chassis ..................................................... 45

Design Recommendations ................................................................................................... 46-49

Ambulance Builder Guidelines ............................................................................................. 50

INDEX 2008 MODEL YEAR

Page Page VEHICLE

DESIGN

COMPONENTS

POWER TAKE-OFF

ELECTRICAL

SECOND UNIT BODY

E-SERIES WAGON MODEL LINEUP

(1) Engine/transmission combinations may not be available on all models, or in all areas.(2) Base curb weight is for standard equipment only.

2008 MODEL YEAR

E-SERIES MODEL

BODY

CODE

WHEELBASE

inches

CA

inches

STANDARD

ENGINE(1)

liters

STANDARD

TRANSMISSION

MAXIMUM

GVWR

pounds

PASSENGER

CAPACITY

BASE CURB WEIGHT(2)

FRONT

pounds

REAR

pounds

TOTAL

pounds

REGULAR / EXTENDED WAGON

E-150 Wagon E11 138 —

4.6L V-6

4-Spd. Auto OD (4R75E)

85207 3175 2649 5824

8 3102 2532 5634

5.4L V-8 86007 3223 2642 5865

8 3173 2544 5717

E-350 Super Duty Wagon E31 138 — 5.4L V-8 4-Spd. Auto OD (4R75E) 8800 12 3251 2773 6024

E-350 Super Duty Extended Wagon S31 138 — 5.4L V-8 4-Spd. Auto OD (4R75E)9300 11 3045 3198 6243

9100 15 2974 3419 6393

Page 1E-SERIES

DIMENSIONAL DATAE-150/E-350 SUPER DUTY WAGON 7-PASSENGERQUAD CAPTAIN’S CHAIRS / 3-PASSENGER BENCH

NOTE — [ ] DIMENSIONS ARE INCHES.

2008 MODEL YEAR

Page 2E-SERIES

NOTE — [ ] DIMENSIONS ARE INCHES

2008 MODEL YEAR

DIMENSIONAL DATAE-150/E-350 SUPER DUTY WAGON 7-PASSENGERQUAD CAPTAIN’S CHAIRS / 3-PASSENGER BENCH

CODE DESCRIPTION7-PASSENGER

QUAD CAPTAIN’S CHAIRS/3-PASSENGER BENCH

EXTERIOR

W410VEHICLE WIDTH (CAB WIDTH MAX WITH:

SAIL MOUNT – MANUAL/POWER MIRROR)2431

[95.7]

W410VEHICLE WIDTH (CAB WIDTH MAX WITH:TRAILER TOW MIRROR)

2692 [106.0]

W410VEHICLE WIDTH (CAB WIDTH MAX WITH:TRAILER TOW MIRROR EXTENDED)

2753 [108.4]

FRONT COMPARTMENT

W305 SEAT TO ENGINE COVER – DRIVER168

[6.6]

W306 SEAT TO ENGINE COVER – PASSENGER155

[6.1]

REAR COMPARTMENT – CARGO

H504 WHEELHOUSE HEIGHT228

[9.0]

H505 CARGO HEIGHT – MAXIMUM1316

[51.8]

L202 CARGO LENGTH – CLOSED FRONT3064

[120.6]

L204 CARGO LENGTH @ BELT – FRONT2802

[110.3]

L512 CARGO LENGTH TO ENGINE COVER3512

[138.3]

W201 CARGO WIDTH BETWEEN WHEELHOUSE1298

[51.1]

W500 CARGO BODY WIDTH @ FLOOR1721

[67.8]

V6 CARGO VOLUME – REAR OF FRONT SEAT – CU. FT. 211.3

Page 3E-SERIES


2008 MODEL YEAR

DIMENSIONAL DATAE-150/350 SUPER DUTY WAGON 8/12-PASSENGER

Page 4E-SERIES

CODE DESCRIPTION

BASEBUCKET8-PASSCARGODOOR


CAPTAIN’SCHAIR8-PASSSLIDINGDOOR

CAPTAIN’SCHAIR

12-PASSSLIDINGDOOR

EXTERIOR

H106C APPROACH ANGLE @ CURB (DEGREES) 23.1* 22.7** 23.1* 22.7**

H107C DEPARTURE ANGLE @ CURB (DEGREES) 20.2* 22.9** 20.2* 22.9**

L101 WHEELBASE3504

[138.0]

L103 VEHICLE LENGTH5505

[216.7]

L104 FRONT OVERHANG888

[35.0]

L105 REAR OVERHANG1113 [43.8]

W103 VEHICLE WIDTH (MAX W/O MIRRORS & W/MOLDINGS)2016[79.4]

W410VEHICLE WIDTH (CAB WIDTH MAX W/

SAIL MOUNT – MANUAL/POWER MIRROR)2431 [95.7]

W410VEHICLE WIDTH (CAB WIDTH MAX W/TRAILER TOW MIRROR)

2692 [106.0]

W410VEHICLE WIDTH (CAB WIDTH MAX W/TRAILER TOW MIRROR EXTENDED)

2753 [108.4]

FRONT COMPARTMENT

W305 SEAT TO ENGINE COVER – DRIVER168

[6.6]

W306 SEAT TO ENGINE COVER – PASSENGER155 [6.1]

CODE DESCRIPTION



CAPTAIN’SCHAIR8-PASSSLIDINGDOOR

CAPTAIN’SCHAIR

12-PASSSLIDINGDOOR


H504 WHEELHOUSE HEIGHT228 [9.0]

H505 CARGO HEIGHT – MAXIMUM1349 [53.1]


[120.6]


[110.3]


[138.3]

W201 CARGO WIDTH BETWEEN WHEELHOUSE1298 [51.1]

W500 CARGO BODY WIDTH @ FLOOR1721 [67.8]

1772 [69.8]

V6 CARGO VOLUME – REAR OF FRONT SEAT - CU.FT. 211.6

REAR COMPARTMENT – SEATING

W8 SEATING WIDTH – 2ND1366

[53.8]

W87 SEATING WIDTH – 3RD1366

[53.8]

W87-4TH SEATING WIDTH – 4TH –1366

[53.8]–

11366 [53.8]

DOOR OPENINGS (ENTRANCE ROOM)

H202REAR OPENING HEIGHT 1189

[46.8]

H508 ENTRANCE HEIGHT – CARGO SIDE 1198 [47.2]

1198 [47.2]

L508 ENTRANCE LENGTH – CARGO SIDE 1138 [44.8]

1006 [39.6]

W203REAR OPENING WIDTH @ FLOOR 1381

[54.4]

W204REAR OPENING WIDTH @ BELT 1377

[54.2]


DIMENSIONAL DATAE-150/350 SUPER DUTY WAGON 8/12-PASSENGER

2008 MODEL YEAR

* E150** E350

Page 5E-SERIES


DIMENSIONAL DATAE-350 SUPER DUTY

EXTENDED WAGON 11/15-PASSENGER2008

MODEL YEARPage 6

E-SERIES

CODE DESCRIPTION

11/15 PASS EXTENDED

BASE BUCKETCARGO DOOR

11/15 PASS EXTENDED

CAPTAIN’S CHAIRSLIDING DOOR

EXTERIOR

H106C APPROACH ANGLE @ CURB (DEGREES) 23.1°

H107C DEPARTURE ANGLE@ CURB (DEGREES) 16.3°

L101 WHEELBASE3505

[138.0]

L103 VEHICLE LENGTH6013

[236.7]

L104 FRONT OVERHANG 887

[34.9]

L105 REAR OVERHANG 1621[63.8]

W103 VEHICLE WIDTH (MAX W/O MIRRORS & W/ MOLDINGS)2016[79.4]


SAIL MOUNT – MANUAL/POWER MIRROR)2431[95.7]

W410VEHICLE WIDTH (CAB WIDTH MAX WITH: TRAILER TOW MIRROR)

2692 [106.0]

W410VEHICLE WIDTH (CAB WIDTH MAX WITH: TRAILER TOW MIRROR EXTENDED)

2753 [108.4]

FRONT COMPARTMENT

W305 SEAT TO ENGINE COVER – DRIVER168[6.6]

W306 SEAT TO ENGINE COVER – PASSENGER155[6.1]

CODE DESCRIPTION

11/15 PASS EXTENDED

BASE BUCKETCARGO DOOR

11/15 PASS EXTENDED

CAPTAIN’SCHAIRSLIDING DOOR


H504 WHEELHOUSE HEIGHT228[9.0]

H505 CARGO HEIGHT – MAXIMUM1329[52.3]


[140.6]


[130.3]


[158.3]

W201 CARGO WIDTH BETWEEN WHEELHOUSE1298[51.1]

W500 CARGO BODY WIDTH @ FLOOR1721[67.8]

1772[69.8]

V6 CARGO VOLUME – REAR OF FRONT SEAT – CU.FT. 249.1 251.7


W8 SEATING WIDTH – 2ND1366[53.8]

W87 SEATING WIDTH – 3RD1366[53.8]

W87-4TH SEATING WIDTH – 4TH (3-PASSENGER)1366[53.8]

W87-5TH SEATING WIDTH – 5TH (4-PASSENGER)1626[64.0]


H202REAR OPENING HEIGHT 1220

[48.0]

H508 ENTRANCE HEIGHT – CARGO SIDE 1199[47.2]

1199[47.2]

L508 ENTRANCE LENGTH – CARGO SIDE 1138[44.8]

1158[45.6]

W203REAR OPENING WIDTH @ FLOOR 1381

[54.4]

W204REAR OPENING WIDTH @ BELT 1377

[54.2]


DIMENSIONAL DATAE-350 SUPER DUTY

EXTENDED WAGON 11/15-PASSENGER2008

MODEL YEARPage 7

E-SERIES

E-SERIES VAN MODEL LINEUP

E-SERIES MODELBODYCODE

WHEELBASEinches

CAinches

STANDARDENGINE(1)

litersSTANDARD

TRANSMISSION(1)

MAXIMUMGVWRpounds

MAXIMUMPAYLOAD(3)

pounds

BASE CURB WEIGHT(2)

FRONTpounds

REARpounds

TOTALpounds

REGULAR / EXTENDED VAN

E-150 Van E14 138 —

4.6L V-6

4-Spd. Auto. OD (4R75E)

8520 3314 2894 2312 5206

8520(4) 3087(4) 3013(4) 2420(4) 5433(4)

5.4L V-88600 3341 2936 2323 5259

8600(4) 3121(4) 3051(4) 2428(4) 5479(4)

E-250 Van E24 138 —

4.6L V-8


8900 3624 2932 2344 5276

8900(4) 3410(4) 3044(4) 2446(4) 5490(4)

5.4L V-89000 3673 2973 2354 5327

9000(4) 3469(4) 3080(4) 2451(4) 5531(4)

E-250 Extended Van S24 138 —

4.6L V-8


8900 3503 2999 2398 5397

8900(4) 3260(4) 3123(4) 2517(4) 5640(4)

5.4L V-89000 3548 3042 2410 5452

9000(4) 3319(4) 3159(4) 2522(4) 5681(4)

E-350 Super Duty Van E34 138 — 5.4L V-8 4-Spd. Auto OD (4R75E)9500 4110(4) 3011 2379 5390

9500(4) 3908(4) 3103(4) 2489(4) 5592(4)

E-350 Super Duty Extended Van S34 138 — 5.4L V-8 4-Spd. Auto OD (4R75E)9500 3967 2903 2630 5533

9500(4) 3742(4) 3012(4) 2746(4) 5758(4)

(1) Engine/transmission combinations may not be available on all models, or in all areas.(2) Base curb weight is for standard equipment only.(3) Includes weight of driver, passengers and optional equipment. (4) Crew Van

2008 MODEL YEAR

Page 8E-SERIES


2008 MODEL YEAR

DIMENSIONAL DATAE-150/250/350 SUPER DUTY VAN

Page 9E-SERIES

CODE DESCRIPTION

REGULAR VAN BASE BUCKET 2-PASS SLIDING DOOR

REGULAR VAN BASE BUCKET 2-PASS

CARGO DOOR

EXTENDED LENGTH VAN

CAPTAIN’S CHAIR 2-PASS CARGO DOOR

EXTERIOR

H106C APPROACH ANGLE @ CURB (DEGREES) 23.3* 24.8**

H107C DEPARTURE ANGLE @ CURB (DEGREES) 22* 16.3**

L101 WHEELBASE 3505[138.0]

L103 VEHICLE LENGTH 5505[216.7]

6005[236.4]

L104 FRONT OVERHANG 879[34.6]


1621[63.8]

W103 VEHICLE WIDTH (MAX W/O MIRRORS & W/ MOLDINGS) 2016[79.4]

W410 VEHICLE WIDTH (CAB WIDTH MAX WITH:SAIL MOUNT — MANUAL/POWER MIRROR)

2430 [95.7]


2692[106.0]


2753[108.4]

FRONT COMPARTMENT

W305 SEAT TO ENGINE COVER — DRIVER 168[6.6]

W306 SEAT TO ENGINE COVER — PASSENGER 155[6.1]


DIMENSIONAL DATAE-150/250/350 SUPER DUTY VAN

CODE DESCRIPTION

REGULAR VAN BASE BUCKET 2-PASS SLIDING DOOR

REGULAR VAN BASE BUCKET 2-PASS

CARGO DOOR

EXTENDED LENGTH VAN

CAPTAIN’S CHAIR 2-PASS CARGO DOOR

REAR COMPARTMENT — CARGO

H504 WHEELHOUSE HEIGHT 240[9.4]

H505 CARGO HEIGHT — MAXIMUM 1369[53.9]

1376[54.2]

L202 CARGO LENGTH — CLOSED FRONT 3084[121.4]

3592[141.4]

L204 CARGO LENGTH @ BELT — FRONT 2818[110.9]

3333[131.2]

L512 CARGO LENGTH TO ENGINE COVER 3523[138.7]

4031[158.7]

W201 CARGO WIDTH BETWEEN WHEELHOUSE 1334[52.5]

W500 CARGO BODY WIDTH @ FLOOR 1870[73.6]

1871[73.7]

W506 CARGO WIDTH @ ROOF RAIL 1559[61.4]

V6 CARGO VOLUME — REAR OF PARTITION — CU.FT. 346.9 407.9


H116 STEP HEIGHT — 2ND 522[20.6]

510[20.1]

H202 REAR OPENING HEIGHT 1258[49.5]

H508 ENTRANCE HEIGHT — CARGO SIDE 1225[48.2]

1221[48.1]

L508 ENTRANCE LENGTH — CARGO SIDE 1006[39.6]

1138[44.8]

W203 REAR OPENING WIDTH @ FLOOR 1378[54.2]

W204 REAR OPENING WIDTH @ BELT 1377[54.2]

* E150

** E350

Page 10E-SERIES

2008 MODEL YEAR


DIMENSIONAL DATAE-150/250/350 SUPER DUTY

CREW VAN – REGULAR / EXTENDED LENGTH2008

MODEL YEARPage 11

E-SERIES


DIMENSIONAL DATAE-150/250/350 SUPER DUTY

CREW VAN – REGULAR / EXTENDED LENGTH

CODE DESCRIPTION

REGULAR LENGTH BASE BUCKET

5-PASS CARGO DOOR

EXTENDED LENGTH

BASE BUCKET 5-PASS

CARGO DOOR

EXTERIOR

H106C APPROACH ANGLE @ CURB (DEGREES) 23.1* 24.8**

H107C DEPARTURE ANGLE @ CURB (DEGREES) 19* 16.3**

L101 WHEELBASE 3504[138.0]

3505[138.0]

L103 VEHICLE LENGTH 5505[216.7]

6005[236.4]

L104FRONT OVERHANG 879

[34.6]


1621[63.8]

W103 VEHICLE WIDTH (MAX W/O MIRRORS & W/ MOLDINGS) 2016[79.4]


SAIL MOUNT – MANUAL/POWER MIRROR)2430[95.7]


2692[106.0]


2753[108.4]

FRONT COMPARTMENT

W305 SEAT TO ENGINE COVER – DRIVER 168[6.6]

W306 SEAT TO ENGINE COVER – PASSENGER 155[6.1]

CODE DESCRIPTION

REGULAR LENGTH BASE BUCKET

5-PASS CARGO DOOR

EXTENDED LENGTH

BASE BUCKET 5-PASS

CARGO DOOR


H504 WHEELHOUSE HEIGHT 241[9.5]

H505 CARGO HEIGHT — MAXIMUM 1369[53.9]

L202 CARGO LENGTH — CLOSED FRONT 3084[121.4]

3592[141.4]

L204 CARGO LENGTH @ BELT — FRONT 2818[110.9]

3326[130.9]

L512 CARGO LENGTH TO ENGINE COVER 3523[138.7]

4031[158.7]

W201 CARGO WIDTH BETWEEN WHEELHOUSE 1334[52.5]

W500 CARGO BODY WIDTH @ FLOOR 1869[73.6]

1869[73.6]

W506 CARGO WIDTH @ ROOF RAIL 1559[61.4]

V6 CARGO VOLUME — REAR OF PARTITION — CU.FT. 146.3 187.0


H116 STEP HEIGHT – 2ND 499[19.6]

510[20.1]

H202 REAR OPENING HEIGHT 1258[49.5]

H508 ENTRANCE HEIGHT – CARGO SIDE 1225[48.2]

L508 ENTRANCE LENGTH – CARGO SIDE 1158[45.6]

W203 REAR OPENING WIDTH @ FLOOR 1369[53.9]

W204 REAR OPENING WIDTH @ BELT 1377[54.2]

2008 MODEL YEAR

* E150** E350

Page 12E-SERIES

NOTES — [ ] DIMENSIONS ARE INCHES.NOTES — F/R - TO FRAME DATUM LINE 633.7 MM (24.95 INCHES); NOTES — TO TOP OF FLOOR BEADS ADD 113.2 MM (4.46 INCHES).

2008 MODEL YEAR

MODELWB[in]

MAXGVWR

[lb] BASE TIRE

F HEIGHT AT WHEEL FRONT(1) R HEIGHT AT AXLE REAR(1) LH (1) CH (1)

AA BB CC* FW RWCURB(2) LOADED(3) CURB(2) LOADED(3) EMPTY LOADED EMPTY LOADED

E-150 WAGON 138 8520 LT225/75R16E614

[24.2]585

[23.0]675

[26.6]593

[23.3]717

[28.2]622

[24.5]2062[81.2]

1987[78.2]

236[9.3]

754[29.7]

333[13.1]

1765[69.5]

1709[67.3]

E-350 SUPER DUTY WAGON 138 8800 LT225/75R16E658

[25.9]627

[24.7]733

[28.8]648

[25.5]777

[30.6]680

[26.8]2118[83.4]

2040[80.3]

236[9.3]

752[29.6]

345[13.6]

1765[69.5]

1687[66.4]

E-350 SUPER DUTY EXTENDED WAGON 13891009300

LT245/75R16E666

[26.2]635

[25.0]756

[29.8]657

[25.9]814

[32.1]690

[27.2]2148[84.6]

2049[80.7]

263[10.3]

780[30.7]

358[14.1]

1763[69.4]

1687[66.4]

E-150 VAN 138 8520 LT225/75R16659

[25.9]629

[24.8]698

[27.5]624

[24.6]708

[27.9]622

[24.5]2080[81.9]

2022[79.6]

218[8.6]

676[26.6]

328[12.9]

1762[69.4]

1692[66.6]

E-150 VAN(4) 138 8520 LT225/75R16659

[25.9]629

[24.8]698

[27.5]624

[24.6]708

[27.9]622

[24.5]2080[81.9]

2022[79.6]

236[9.3]

754[29.7]

333[13.1]

1762[69.4]

1692[66.6]

E-250 VAN 138 8900 LT245/75R16E658

[25.9]627

[24.7]745

[29.3]646

[25.4]765

[30.1]669

[26.3]2126[83.7]

2049[80.7]

236[9.3]

752[29.6]

345[13.6]

1763[69.4]

1691[66.6]

E-250 VAN EXTENDED VAN 138 8900 LT245/75R16E666

[26.2]635

[25.0]719

[28.3]645

[25.4]783

[30.8]658

[25.9]2148[84.6]

2049[80.7]

236[9.3]

752[29.6]

345[13.6]

1763[69.4]

1691[66.6]

E-350 SUPER DUTY VAN 138 9500 LT245/75R16E666

[26.2]635

[25.0]741

[29.2]658

[25.9]765

[30.1]669

[26.3]2126[83.7]

2049[80.7]

263[10.3]

767[30.2]

358[14.1]

1763[69.4]

1687[66.4]

E-350 SUPER DUTY EXTENDED VAN 138 9500 LT245/75R16E666

[26.2]635

[25.0]756

[29.8]657

[25.9]814

[32.1]690

[27.2]2148[84.6]

2049[80.7]

263[10.3]

767[30.2]

358[14.1]

1763[69.4]

1687[66.4]

(1) THE HEIGHT DATA SHOWN REPRESENTS DIMENSIONS OF A BASE/STANDARD VEHICLEWITH NO OPTIONS, ACTUAL HEIGHT MAY VARY DUE TO PRODUCTION TOLERANCES.

(2) HEIGHT AT BASE CURB WEIGHT WITH STANDARD SPRINGS.(3) LOADED HEIGHT AT SPRING RATING WITH STANDARD SPRINGS.(4) RV CONVERSION..

* — STATIC LOADED RADIUS REPRESENTS AXLE TO GROUND WITH MAXIMUM

RATED LOAD ON TIRE AT MAXIMUM PRESSURE.L C

AXLE/TIRE/VEHICLE HEIGHT DATAE-SERIES WAGON / VAN

Page 13E-SERIES


INCOMPLETE E-150/250/350 SUPER DUTYRECREATIONAL VAN

NOTE: This sketch identifies the locations in 138-inchwheelbase regular length E-Series Recreational vanswhere Ford Motor Company provides anchorages forattachment of the upper or “D-ring” ends of the torsorestraints for second and third row seats that

maybe installed by subsequent-stage manufacturers.The longitudinal distances from the vertical referenceline for the second and third row seat anchorages are116.4 inches and 158.5 inches, respectively.

NOTE: If a left-hand, second-row seat is installed, ananchorage must be installed by the subsequent-stagemanufacturer on the left side of the vehicle at 16.4inches. (This anchorage should be locatedsymmetrically opposite the corresponding right-handanchorage installed by Ford Motor Company.) A nutmounted to a reinforcement plate and four rivets are

furnished for this purpose with the incomplete vehicle aspart of the Recreational trim. The sketch also identifiesthe rearmost seating reference points (SgRP’s) forsecond and third row seats that may be installed. Theseare 106.1 inches and 148.4 inches (longitudinal),respectively. Call the Ford Truck Body Builders AdvisoryService if there are any questions regarding this sketch.

2008 MODEL YEAR

Page 14E-SERIES


E-SERIESFUEL SYSTEM EVAPORATIVE EMISSIONS

2008 MODEL YEAR

Page 15E-SERIES

E-SERIES MODEL

BODYCODE

WHEELBASEinches

CAinches

STANDARDENGINE(1)

litersSTANDARD

TRANSMISSION

MAXIMUMGVWRpounds

MAXIMUM PAYLOAD(3)

pounds

BASE CURB WEIGHT(2)

FRONTpounds

REARpounds

TOTALpounds

COMMERCIAL / RV CUTAWAY

E-250 Super Duty Cutaway E25 138 80 4.6L V-8 4-Spd. Auto OD (4R75E) 8600 SRW 4339 2879 1382 4261

E-350 Super Duty Cutaway

E37

138 80 5.4L V-8

4-Spd. Auto OD (4R75E) 9600 SRW 4909 2924 1767 4691

E35

5-Spd. Auto OD (TorqShift™)9600 SRW 4849 2954 1797 4751

11,500 DRW 6578 2968 1954 4922

158 1005.4L V-8 5-Spd. Auto OD (TorqShift™) 12,500 DRW

7514 2956 2030 4986

176 118 7506 3028 1966 4994

E-450 Super Duty Cutaway E45158 100

5.4L V-8 5-Spd. Auto OD (TorqShift™) 14,050 DRW 8723 2887 2440 5327

176 118 8665 3015 2370 5385

COMMERCIAL STRIPPED CHASSIS

E-350 Super Duty Commercial Stripped Chassis E39

138 —5.4L V-8

5-Spd. Auto OD (TorqShift™)

9000 SRW 4900 2247 1853 4100

10,000 DRW 5633 2255 2112 4367

11,500 DRW 7133 2255 2112 4367

158 — 5.4L V-8 5-Spd. Auto OD (TorqShift™)

9600 SRW 5415 2356 1829 4185

10,000 DRW 5708 2345 1947 4292

12,500 DRW 8073 2315 2112 4427

176 — 5.4L V-8 5-Spd. Auto OD (TorqShift™)10,000 DRW 5514 2369 2117 4486

12,500 DRW 8014 2369 2117 4486

E-450 Super Duty Commercial Stripped Chassis E49158

— 5.4L V-8 5-Spd. Auto OD (TorqShift™)14,050 DRW

9409 2335 2306 4641

176 9357 2370 2323 4693

E-SERIES SUPER DUTY CUTAWAY / STRIPPED CHASSIS

MODEL LINEUP

(1) Engine/transmission combinations may not be available on all models, or in all areas.(2) Base curb weight is for standard equipment only.(3) Includes weight of driver, passengers and optional equipment. (4) School Bus only.

2008 MODEL YEAR

Page 16E-SERIES


2008 MODEL YEAR

DIMENSIONAL DATAE-250/350 SUPER DUTY CUTAWAY

138" WHEELBASE (SRW)Page 17

E-SERIES

NOTES — [ ] DIMENSIONS ARE INCHES.NOTE — FOR CA DIMENSIONS, SEE MODEL LINE UP.

2008 MODEL YEAR

DIMENSIONAL DATAE-350 SUPER DUTY CUTAWAY138" WHEELBASE (SRW/DRW)

Page 18E-SERIES


DIMENSIONAL DATAE-350 SUPER DUTY CUTAWAY

138" WHEELBASE (SRW/DRW)2008

MODEL YEARPage 19

E-SERIES

DIMENSIONAL DATA

E-350/450 SUPER DUTY CUTAWAY158" WHEELBASE (DRW)

NOTES — [ ] DIMENSIONS ARE INCHES.NOTE — FOR CA DIMENSION, SEE MODEL LINE UP.

2008 MODEL YEAR

Page 20E-SERIES

NOTE — [ ] DIMENSIONS ARE INCHES.TE —


158" WHEELBASE (DRW)2008

MODEL YEARPage 21

E-SERIES

NOTES — [ ] DIMENSIONS ARE INCHES..NOTE — FOR CA DIMENSION, SEE MODEL LINEUP.

2008 MODEL YEAR


176" WHEELBASE (DRW)Page 22

E-SERIES

A

C

1445[56.9]

1283

CLREAR AXLE

470[18.5]

482[19.0] TOP OF FRAME

SPACERS102[4.0]

TOP OFFRAME

DIA HOLE IN FRAME36 [1.41]

SEC

BOLTS & BODYMOUNTS INDUNNAGEPACKAGESTORQUE TO

68[2.7]

OUTSIDE MOUNTEDSTEEL PLATE [4 X 12 X 1/4 IN]WELDED AND BOLTED[7/16 - 14 X 1.00 GRADE 8BOLTS AND NUTS]

FRAME EXTENSION 1/4 IN. THICK(CHAMFERED AND BUTT-WELDED

D 160[6.3]

76[3.0]

457�7.6[18�0.3]

70 � 10.5Nm

“C” CHANNEL) *

BB0661

51[2.0]

61[2.4] 122

[4.8]

DIA

51[2.0]

196[7.7]

457[18.0]

741[29.2]

FRONT OF

122[4.8]

617[24.3]REF

CL

1036[40.8]

855[33.6]

457[18.0]

61[2.4]

NEW 35 [1.39] DIA HOLE

FREESTATE

SPACER DIMENSIONS

DIA = 12.7[.50]

SPACER

SPACER

SPACER

74[2.91]

1481

[24.25]

9888 HOLES

57[2.26]

74

[58.3]1481

[38.9]

204[37.7]

988

616

8 HOLES

6 HOLES

SPACER

SPACER

SPACER

SPACER

SPACER

SPACER

VEHICLE

SPACER

SPACER SPACER SPACER SPACER SPACER

B

B

SYM CL

FRONT OFVEHICLE

35 [1.39]

IN SPACER FRAMEEXTENSION

A

A

G

E

E

A

A

C

C

FF

B

AB

AA

C

B

D E F G

A

B

[50.5]

28[1.1]

FREESTATE

[2.91]

[58.3] [38.9]


176" WHEELBASE (DRW)

NOTES — [ ] DIMENSIONS ARE INCHES.NO TE — *[ FOR NGV VARIANT A “C” CHANNEL FRAMENO NO TE — *[ REINFORCEMENT IS REQUIRED ALONG WITH NO TE — *[ THE FRAME EXTENSION.

2008 MODEL YEAR

Page 23E-SERIES

FUEL FILLER

TOP OF FRAMEKICKUP AT OF REAR AXLECL

NORMAL TOPOF FRAME

CLREAR AXLE

FRAMEOUTSIDE

37 GALLON CAPACITYSTANDARD FUEL TANK

FUEL FILLER LOCATION,SEE NOTES

BB0031−2004

1980[78.0]

220[8.7]

477[18.8]

566[22.3]

854[33.6]

617[24.3]

1283[50.5]

696

1036[40.8]

617[24.3]

[27.4]

1067[42.0]493

[19.4]

985[38.8]

978[38.5]

156[6.1]

775 [30.5]

1142[45.0]

686[27.0]

371

52[2.1] 102

[4.0]

CLFRONT AXLE

3505 [138.0] WHEELBASEOVERALL LENGTH6020 [237.0]

1740 [68.5]

8.2[3.24]

[14.6]

64[2.5] EXHAUST OUTLET289

[11.4]

390[15.3]

434[17.1]

660[26.0]

1298[51.1]

EVAP VALVE63[2.5]

CL VEHICLECL ENGINE

810[31.9]

SgRP

1045[41.1]

F

R

SRW

DRW

EXTENSION

336[13.2]

70[2.7]

40


DIMENSIONAL DATAE-350 SUPER DUTY STRIPPED CHASSIS

138" WHEELBASE (SRW/DRW)2008

MODEL YEARPage 24

E-SERIES


2008 MODEL YEAR

DIMENSIONAL DATAE-350/450 SUPER DUTY STRIPPED CHASSIS


E-SERIES

WITH 158" WHEELBASE.FUEL FILLER

TOP OF FRAMEKICKUP AT OF REAR AXLECL

NORMAL TOPOF FRAME

CLREAR AXLE

FRAMEOUTSIDE

FUEL FILLER LOCATION,SEE NOTES

BB0542 2004

1980[78.0]

220[8.7]

854[33.6]

1445[56.9]

1283[50.5]

6961036 [40.8]

[27.4]

1067[42.0]493

[19.4]

985[38.8]

156[6.1]

775 [30.5]

1142[45.0]

686[27.0]

371

52[2.1] 102

[4.0]

CLFRONT AXLE

4470 [176.0] WHEELBASEOVERALL LENGTH6528 [257.0]

63[2.5]

1283 [50.5]

8.2[3.2]

[14.6]

64[2.5]

289[11.4]

390[15.3]

434[17.1]

[18.0] 457 REQUIRED FRAME EXTENSION WITH

55 GALLON TANK FOR DETAILEDSPECIFICATIONS SEE PAGE 129.

EVAP VALVE

EXHAUSTOUTLET

1740 [68.5]WITH 55 GALLON TANK

,

483[19.0]

470[18.5]

55 GALLON FUEL TANK ISSTANDARD ON ALL E-450AND OPTIONAL ON E-350

37 GALLON FUEL TANK ISSTANDARD ON ALL E-350.

C L VEHICLEC L ENGINE

SgRP

1045[41.1]

F

R

[51.1] 1298

DRW

EXTENSION

336[13.2]

477[18.8]

566[22.3]

70 [2.75]

810[31.9]

40

660 [26.0]


2008 MODEL YEAR

DIMENSIONAL DATAE-350/450 SUPER DUTY STRIPPED CHASSIS


E-SERIES

TH

TW

RWOW

FW

TW

TH

1

1

C

FRONT SUSPENSION

CL VEHICLE

CLEARANCE

REAR VIEWMAX. RIGHT TURN

MAX. LEFT TURN

LEFT FRONT TIRE

TW L

TW R

VEHICLEPLAN VIEW

CL

E 350

E 450

1

FRONT VIEW

BB0029 2003

12.7[0.5]

25.4[1.0]

MIN. CLEARANCE

MIN. CLEARANCE

350[13.8]

CLVEHICLE

[6.5]

[10.0]

25.4[1.0] MIN.

12.7[0.5] MIN. CLEARANCENORMAL TOP

OF FRAME

7800 LB AXLE USED AT 10,000 11,000 LB GVWRFOR RPO APPLICATIONS

1

8000 LB AXLE DSO USE ONLY2

3 9450 LB AXLE USED AT 14,050 LB GVWR FOR E 450

REAR SUSPENSION (DRW)

NORMAL TOPOF FRAME

165

2 [6.6]168

3 [7.0]178

254

56[2.2]71

[2.8]

NORMAL TOPOF FRAME

REAR VIEWREAR SUSPENSION (SRW)

13[0.5] MIN. CLEARANCE

25[1.0] MIN. CLEARANCE

TW

1 [6.1]155

CLVEHICLE

RW

7800 LB AXLE USED AT 10,000 11,000 LB GVWRFOR ALL RPO APPLICATIONS

1

OW

TH[1.7]43


FRONT SUSPENSION

TIRE TW 1 TH 1 TW L TW R

LT225/75R16E 655[25.8]

302[11.9]

549[21.6]

521[20.5]

LT245/75R16E 655[25.8]

320[12.6]

549[21.6]

521[20.5]

AXLE / TIRE / WHEELHOUSE / VEHICLE HEIGHT DATASUPER DUTY CUTAWAY / STRIPPED CHASSIS

ALL WHEELBASES (SRW/DRW)

LC

2008 MODEL YEAR

TW = DISTANCE FROM OF VEHICLE TOSIDE OF TIRE IN MODIFIED JOUNCE.

TH = DISTANCE FROM NORMAL TOP OF FRAME TO TOP OF TIRE IN MODIFIED JOUNCE.

Page 27E-SERIES


AXLE / TIRE / WHEELHOUSE / VEHICLE HEIGHT DATAE-SERIES SUPER DUTY

CUTAWAY / STRIPPED CHASSIS

MODELWB

inchesGVWRpounds MINIMUM TIRE

FRONT GAWRMIN/MAXpounds

F HEIGHT AT FRONT AXLE (1)

REAR GAWR MIN/MAX pounds

COMBINED REAR SPRING

CAPACITY RATE pounds

R HEIGHT AT REAR AXLE (1)

CH OVERALL HEIGHT OF

VEHICLE (STANDARD SPRINGS)(1)

mm [in]

COMBINED FRONT SPRING

CAPACITY RATE pounds

BASE CURB WEIGHT mm [in]

LOADED mm [in]

BASE CURB WEIGHT mm [in]

LOADED mm [in]

STD SPRING STD SPRING STD SPRING STD SPRING STD SPRING STD SPRING CURB LOADED

CUTAWAY

E-250 138 8600 LT225/75R16E 3800 3800 551 [21.7] 521 [20.5] 5360 5545 605 [23.8] 528 [20.8] 2065 [81.3] 2016 [79.4]

E-350 SD

138

9600(2) LT245/75R16E 3700/4600(3) 3700/4600(3) 561 [22.1] 530 [20.9] 6084 7810 666 [26.2] 586 [23.1] 2096 [82.5] 2045 [80.5]

10,700 LT225/75R16E 3700/4600(3) 3700/4600(3) 553 [21.8] 522 [20.6] 7800 7810 658 [25.9] 576 [22.7] 2085 [82.1] 2035 [80.1]

11,500(4) LT225/75R16E 4050 4050 553 [21.8] 522 [20.6] 7800 7810 658 [25.9] 576 [22.7] 2085 [82.1] 2035 [80.1]

158 11,500 LT225/75R16E 4050/4600(3) 4050/4600(3) 553 [21.8] 522 [20.6] 7800 7810 658 [25.9] 576 [22.7] 2080 [81.9] 2032 [80.0]

176 11,500 LT225/75R16E 4050/4600(3) 4050/4600(3) 553 [21.8] 522 [20.6] 7800 7810 658 [25.9] 576 [22.7] 2078 [81.8] 2030 [79.9]

E-450 SD

158 14,050 LT225/75R16E 4600 4600 553 [21.8] 522 [20.6] 9450 9450 662 [26.0] 577 [22.7] 2083 [82.0] 2032 [80.0]

176 14,050 LT225/75R16E 4600 4600 553 [21.8] 522 [20.6] 9450 9450 662 [26.0] 577 [22.7] 2078 [81.8] 2030 [79.9]

STRIPPED CHASSIS

E-350 SD

138 9600(2) LT245/75R16E 3550/3800 3550/3900 — 530[20.9] 6084 7810 — 586 [23.1] — —

10,000 LT225/75R16E 3700/3800 3700/3900 — 522 [20.6] 7800 7810 — 576 [22.7] — —

158

9600(2) LT245/75R16E 3550/3800 3550/3800 — 530[20.9] 6084 7810 — 586 [23.1] — —

10,000 LT225/75R16E 3550/3800 3550/3800 — 522 [20.6] 7800 7810 — 576 [22.7] — —

11,000 LT225/75R16E 3800/4200 3800/4200 — 522 [20.6] 7800 7810 — 576 [22.7] — —

17610,000 LT225/75R16E 3800/4050 3800/4050 — 522 [20.6] 7200 7810 — 576 [22.7] — —

11,000 LT225/75R16E 4050/4400 4050/4400 — 522 [20.6] 7800 7810 — 576 [22.7] — —

E-450 SD158 14,050 LT225/75R16E 4600 4600 — 522 [20.6] 9450 9450 — 577 [22.7] — —

176 14,050 LT225/75R16E 4600 4600 — 522 [20.6] 9450 9450 — 577 [22.7] — —

2008 MODEL YEAR

(1) The Height Data shown represents dimensions of a nominal vehicle with no options. Actual height may vary due to production tolerances.

(2) Single Rear Wheels.

(3) 4600 lb. Standard with Ambulance Prep Package.

(4) School Bus Prep Package.

Page 28E-SERIES

MODEL TIRE SIZE

ALL SEASON TIRE DATATREAD WIDTH OW TH TW GROUND CLEARANCE

A B C FW RW OVERALL WIDTH

STD STDG J

APPROACH ANGLE DEPARTURE ANGLE

STATIC LOADED RADIUS

MAX. DIAMETER

MAX. SECTION WIDTH

RIM WIDTH

FRONT REAR REAR SPRING SPRING138"WB

158"WB

176"WB

138"WB

158"WB

176"WB

E-250 Cutaway SRW LT225/75R16E 346[13.6]

757[29.8]

236 [9.3]

152 [6.0]

1763[69.4]

1692[66.6]

1915[75.4]

307[12.1]

653[25.7]

23° N/A N/A 21° N/A N/A

E-350 Cutaway SRW LT245/75R16E 356[14.0]

787 [31.0]

263 [10.3]

178 [7.0]

1763 [69.4]

1831 [72.1]

2094[82.4]

307 [12.1]

710 [28.0]

23° N/A N/A 18° N/A N/A

E-350 Cutaway DRW LT225/75R16E 346 [13.6]

757[29.8]

236 [9.3]

152 [6.0]

1763 [69.4]

1860 [73.2]

2349[92.5]

329[12.9]

684 [26.9]

23° 23° 23° 18° 15° 18°

E-350 Stripped Chassis SRW LT245/75R16E 356[14.0]

787[31.0]

263 [10.3]

178 [7.0]

1763 [69.4]

1831 [72.1]

1950 [76.7]

298 [11.7]

638 [25.1]

34° 34° N/A 18° 18° N/A

E-350 Stripped Chassis DRW LT225/75R16E 346[13.6]

757[29.8]

236 [9.3]

152 [6.0]

1763 [69.4]

1860 [73.2]

2349[92.5]

329[12.9]

684 [26.9]

33° 33°34°

18° 18° 24°

E-450 Cutaway DRW LT225/75R16E 346 [13.6]

757[29.8]

236 [9.3]

152 [6.0]

1763 [69.4]

1974 [77.7]

2464 [97.0]

325[12.8]

743 [29.2]

N/A 33° 33° N/A 15° 18°

E-450 Stripped Chassis DRW LT225/75R16E 346 [13.6]

757 [29.8]

236 [9.3]

152 [6.0]

1763 [69.4]

1974 [77.7]

2464 [97.0]

325[12.8]

743 [29.2]

N/A 33° 35° N/A 15° 18°

900

1200

165185165

900

1200CL

JG

GROUND LINE

APPROACH ANGLEAT GVWR

STATIC LOADED RADIUS

TIRE DIAMETER

"A"

"B" DEPARTURE ANGLEAT GVWR

MINIMUM GROUND CLEARANCE LINEAT GVWR (LOADED) − COMPONENTSTHAT COULD DISABLE A VEHICLESHOULD BE 30.0 [1.18] ABOVETHE MINIMUM CLEARANCE LINE.BB0676


GROUND CLEARANCE DATASUPER DUTY CUTAWAY / STRIPPED CHASSIS

BASE VEHICLE LOADED

2008 MODEL YEAR

55-gallon tank and 18 inch frame extension.

Page 29E-SERIES

NOTES — [ ] DIMENSIONS ARE INCHES.NOTES — ** PLACEMENT FOR GAS ENGINES AUXILIARY BATTERY OPTION

2008 MODEL YEAR

BATTERY BOX LOCATIONSE-350/450 DUAL AND GAS AUXILIARY

The guidelines below must be followed when repositioning the battery box

• Maintain attachment hole diameter of (12 mm)

• Maintain use of existing OEM bolts (M10)

• The battery box must NOT be packaged any lower in vehicle position than is provided by Ford

• All new frame holes must be at least 1x hole diameter away from all other holes & 1½ diameter away from the edge of a radius tangent

• Battery boxes may not be moved rearward of position provided by Ford

Page 30E-SERIES


FUEL FILLER SYSTEME-SERIES SUPER DUTY CUTAWAY / STRIPPED CHASSIS

2008 MODEL YEAR

Page 31E-SERIES

WARNING

18 INCH MIN. FRAMEEXTENSION REQUIREDWITH THE 55 GAL. TANK

AND THE 176" WHEELBASE ONLY


AFT-OF-AXLE FUEL TANKE-350/450 SUPER DUTY

CUTAWAY / STRIPPED CHASSIS2008

MODEL YEARPage 32

E-SERIES


2008 MODEL YEAR

FUEL SYSTEM EVAPORATIVE EMISSIONSE-SERIES SUPER DUTY CUTAWAY / STRIPPED CHASSIS

Page 33E-SERIES

BB0671−2004

3.94

7.87

1.97

1.97

1.97

1.97

1.97

1.97

1.97

1.97

11.81

15.75

19.68

23.62

27.56

31.50

0 CL OF VEHICLE

1.19

1.19

1.16

1.12

1.071.00

1.00

0.92

0.83

0.72

0.59

0.44

0.27

0.06

0.20

0.53

1.97

1.97

1.971.97

1.97 1.97 1.97 1.97 1.971.97

1.97

0.98

0.81

1.15

0.91

2.31 2.32

1.56

0.21

0.86 0.39

0.94

2.031.25

2.49 1.620.93

0.65

0.23

0.42

0.090.07

0.66

0.42

0.03

0.08

0.060.10

0.27

1.08

3.290.35

3.00

0.54

3.22

1.83

3.08

0.17

3.16

3.02 0.94

0.31

2.62

1.971.52

1.610.43

0.37

TOP OF FRAME

SPACERS

TOP OF FRAME

35.43

39.39

82.68 78.74 74.80 70.87 66.93 63.00 59.05 55.12 51.18 47.24 43.30 39.37 35.43 31.50 27.56 23.62 19.68

31.50

35.43

39.37

4.0

9.48

1.97

BACK OF CUTAWAY CAB — PROFILE DIMENSIONSE-250/350/450 SUPER DUTY CUTAWAY

BODY “SECTION A”


2008 MODEL YEAR

Page 34E-SERIES

SEAT POSITIONE-250/350/450 SUPER DUTY CUTAWAY


2008 MODEL YEAR

SRP INFORMATION(SEAT POSITION IS 10.0 mm [0.39] FORWARD OF REARMOST POSITION)

POINT A(SEAT POSITION IS AT THE MIDPOINT OF AVAILABLE TRAVEL)

A B C D E F

DRIVER – SEAT 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 277.3[10.92]

103.0[4.06]

377.0[14.84]

412.0[16.22]

65.0[2.56]

960.1[37.80]

CODE DESCRIPTION

FRONT COMPARTMENT

L34 MAXIMUM EFFECTIVE LEG ROOM – FRONT 1016 [40.0]

W3 SHOULDER ROOM – FRONT 1729 [68.1]

W5 HIP ROOM – FRONT 1664 [65.5]

W117 BODY WIDTH AT H-POINT 1999 [78.6]

H61 EFFECTIVE HEAD ROOM – FRONT 1070 [42.1]

Page 35E-SERIES

SEAT TRACK TRAVEL / H-POINT LOCATIONE-SERIES

NOTES — [ ] DIMENSIONS ARE INCHES.NOTES — THIS INFORMATION IS PROVIDED TO ASSIST IN THE NOTES — INSTALLATION OF SEATS OTHER THAN FORD NOTES N INSTALLED SEATS AND TO HELP PRESERVE THE NOTES — INTENDED PERFORMANCE OF THE SAFETY AND NOTES — ERGONOMIC FEATURES OF THE E-SERIES. NOTES — NOTES THE MID-TRACK H-POINT LOCATION MUST BE NOTES — MAINTAINED IN ORDER TO COMPLY WITH F/CMVSS NOTES — 208 AIRBAG REQUIREMENTS.

2008 MODEL YEAR

Page 36E-SERIES

POWER TAKE-OFF (PTO) APPLICATIONSWIRING LOCATIONS

2008 MODEL YEAR

F250/350/450/550 Cabin / Instrument Panel

• Blunt-cut access wires for SEIC, “Customer Access” signal circuits forCTO, VSO, PARK, PARK-NEUTRAL, and 4 pass-thru wires, arebundled together at the harness above the parking brake pedalassembly,

• Blunt-cut access wires for the 4 optional “Upfitter Switches” are at theharness behind the Power Distribution Junction Box. Pull the PDJBaway from the instrument panel for better access as shown.

F250/350/450/550 Engine Compartment

• The 4 blunt-cut pass-thru wires are found in the harness below the cowl,just outboard of the brake master cylinder, as shown.

E250/350/450 Engine Compartment

• Blunt-cut access wires for SEIC, and the “Customer Access” signalcircuits for CTO, VSO, PARK, PARK-NEUTRAL, are with the largeharness running below the windshield/cowl. Remove some of the plasticsupport gutter above the engine air induction tube to reveal the blunt-cutwires.

• The two pass-thru wires are part of the same modified vehicle wiring kitas prior years. Located at the 4-pin connector in the harness below thecowl, outboard of the brake master cylinder, as shown. Mating pigtailconnector, 4C24-14A411, found in dunnage. Opposite ends locatedabove driver-side kick-panel.

Page 37SEIC / PTO

F-SUPER DUTY F-SUPER DUTY

ELECTRICAL WIRING CUSTOMER ACCESS CIRCUITS

1. Super Duty F-Series and selected E-Series SuperDuty vehicles are equipped with a number ofconveniently located electrical wiring taps. Most tapsare fused, having locations under the instrumentpanel, in the engine compartment, and at the rear ofthe frame. Illustrations, schematics and a wiringharness for Trailer Tow is provided in a cardboardbox shipped with each vehicle. The circuits at therear of the frame are provided to support trailerwiring requirements or the Second Unit Body (SUB)additions. The E-Series and Super Duty F-SeriesCircuit charts have a brief description of each circuitfunction, wire gauge, color code and electricalschematic.

1. The Ford starting and the charging system shouldnot be altered.

2. The completed vehicle total electrical load must notexceed the maximum output of the alternator.

3. Do not route or attach electrical wires to fuel lines.

4. Engine compartment wiring must not be rerouted inany manner.

5. The 6.4L diesel engine requires two batteries wiredin parallel for proper starting operation and must notbe isolated. Do not modify the Glow Plugs PowerCircuits.

6. Ford recommends that all additional underhood andunderbody wiring:

• be cross-linked polyethylene, or equivalent, hightemperature insulation wire 125° C [257° F]minimum rating.

• meet SAE specifications J1128 type SXL, GXL orTXL.

• meet SAE J1127 type SGX or STX for batterycables.

• be protected with nylon convoluted tubing.• be located so as to avoid or minimize restriction

of airflow through the engine compartment,underbody and fuel system.

• be of sufficient length to be properly routed, so asnot to interfere with operating zones of suchcomponents as throttle or transmission linkage.

• not be routed near the exhaust system or noother source of high heat; melted insulation canresult in electrical shorts and system failure.

• be routed away from hostile surfaces and sharpedges and be secured in its intended location.

• be protected by rubber grommets when it passesthrough body or frame openings. Use customeraccess pass-thru circuits provided on Super DutyF-Series to avoid additional openings betweenpassenger and engine compartments.

• be protected from electrical shorts by fuses orcircuit breakers.

• be routed at least 38 mm [1.5 in] away fromengine.

7. Interior wiring not exposed to high temperaturesmay be SAE approved, general purpose wire.

8. Ground the second unit body to the frame in atleast two locations, and if required, add anadditional frame to engine ground cable to improvethe ground path to the battery.

9. Splicing into circuitry relating to the powertraincontrol systems is not acceptable because of theadverse effect on the electrical system operation.

10. Batteries must be disconnected before welding tobody and chassis components. Note thatdisconnecting the batteries will result in a memoryloss on electronic engine/ transmission controlledvehicles. The vehicle will require several miles ofdriving in various driving modes to restore itsmemory and regain optimum operating conditions.

11. Electrical connections exposed to the elementsshould be appropriately protected.

12. Do not ground the body to the transmission ortransmission crossmember.

13. Ignition circuit of any engine should not be altered.

14. Alternator circuit wiring must not be altered bycutting, soldering or splicing.

15. Some head lamps are plastic and have protectivecoatings which can be damaged by solvents ortape. Refer to the Owner’s Guide for propercleaning procedures.

16. For convenience Super Duty F-Series has (4) 14ga. blunt-cut pass-thru circuits located in the cabinwithin a bundle above the parking brake pedal andfound in the engine compartment in a harnessbelow the cowl, just outboard of the brake mastercylinder. E-Series also has (2) 12 ga. pass-thrucircuits located in the cabin above the driver-sidekick-panel in a 6-pin connector (F7UB-14A41-B)and found in the engine compartment at the 4-pinconnector (F4UB-14A411-A) in a harness belowthe cowl, outboard of the brake master cylinder.These circuits provide an unfused means tointerface wiring between the cabin and the enginecompartment without drilling through the dashpanel. Refer to Quality Bulletin Q-108 and theCustomer Access Circuits charts for furtherinformation regarding pass-thru circuits.

17. Center High Mounted Stop Lamp (CHMSL) wiringtaps are provided on E-Series Super DutyCutaway/Stripped Chassis and Super Duty F-Series Chassis Cab vehicles.

18. Electrical bulbs are listed in the Owner’s ManualBulb Chart. Check for the “DOT” marking on thebulb base which means the bulb meets U.S. “DOT”standards. Bulbs without the “DOT” marking or thatproduce different colors other than the originalbulbs as listed in the bulb chart, may affect thelamps light output, aim, glare and your safety; inaddition, such bulbs may burn out early or damagethe lamp.

19. Super Duty F-Series vehicles are equipped with aclean tachometer output (CTO) wiring tap. The tapis designated circuit 76 (LG/WH) and is locatedunder dash near the parking brake pedal. This tapshould be used if a tachometer signal is required.The signal is digital and requires a digitaltachometer. The signal pulse rate is half thenumber of engine cylinders per revolution (i.e., 4 for5.4L gas, 6.4L Diesel, and 5 for 6.8L gas). E-Seriesvehicles are also equipped with CTO wiring tap.The tap is designated circuit 648 (WH/PK) and islocated under hood near the PCM connector.

20. Super Duty F-Series vehicles equipped with the6.4L Diesel engine have two additional outputwiring taps. The taps are the vehicle speed out(VSO) and throttle position out (TPO). The VSO tapis designated circuit 239 (WH/OG) and the TPO tapis designated circuit 1857 (YE/WH). Both taps arelocated under dash near the parking brake pedal.The VSO tap signal frequency is 2.22 times thevehicle speed in miles per hour. The TPO tap is apulse width modulated output from 0 - 100% of5.1kHz signal.

2008 MODEL YEAR

Page 38ELECTRICAL

STRIPPED CHASSIS IS PROVIDED IN A DETAILEDSCHEMATIC WHICH IS PACKAGED WITH THEBODY BUILDER ELECTRICAL CONNECTORS.

BB0481

UNWRAP TAPE FROMHARNESS IN THIS AREAAND REMOVE JUMPERCONNECTION TO EXPOSE

FRONT OFVEHICLE

THE “CHMSL” ELECTRICAL CONNECTION FOR A

TO INSTALL

THE “CHMSL CONNECTOR” .

“CHMSL”

E-SERIES ELECTRICAL WIRINGCUSTOMER ACCESS CIRCUITS

2008 MODEL YEAR

CircuitNumber

ColorCode

WireGauge

Functional Description

14 BR 14 Marker lamp feed to electric brake controller

43 DB 12 Electric tailer brake controller to trailer

49 O 10 Relay feed ignition run

22 LB/BK 12 Trailer brake controller or B+ feed

52 Y 18** Fused left hand stop/turn

64 DG 18** Fused right hand stop/turn

206 W 14* Ground

511 LG 18 Center high mount or lamp feed stop

962 BR-W 14 Relay feed marker lamps

963 BK-LG 12 Relay feed backup lamps

867 DB 12 Customer pass thru circuits

868 GY-R 12 Customer pass thru circuits

53 BK-LB 18 Courtesy lamps

54 LG-Y 18 Courtesy switch feed

3 LG/W 18 Left turn signal

2 W/LB 18 Right turn signal E-SERIES SUPER DUTY CUTAWAY/STRIPPED CHASSIS

* 10 for 7-pin Trailer Tow Connector

** 14 for 7-pin Trailer Tow Connector

Page 39ELECTRICAL

2008 MODEL YEAR

ELECTRONIC BRAKE CIRCUITS

RECOMMENDED MAX ALLOWABLE

WIRE LENGTH (feet)

CIRCUiT COLOR CODE DESCRIPTION 14 AWG 12 AWG 10 AWG

Dark Blue DB Trailer Electric Brake 50 50 50

Orange O Trailer Battery Feed N/A 20 35

Yellow Y Trailer LH Turn/Stop Lamp 50 50 50

Dark Green DG Trailer RH Turn/Stop Lamp 50 50 50

White W Trailer Ground N/A N/A 10 GA only

Brown-White BR-W Trailer Run Lamps 50 50 50

Black-Light Green BK-LG Trailer Back-Up Lamps 50 50 50

ELECTRONIC BRAKE CIRCUITSDark Blue DB Trailer Electric Brake

Brown BR Vehicle Tail Lamp and Marker Lamp

Red R Vehicle Control Feed

Light Green LG Vehicle Brake Signal

White W Trailer Ground

VEHICLE CIRCUIT

Orange-Light Blue O-LB Vehicle RH Rear Turn Signal

Light Green-Orange LG-O Vehicle LH Rear Turn Signal

Black-Pink BK-PK Vehicle Back-Up Lamp Feed

Yellow Y Vehicle Battery Feed

White-Purple W-P Vehicle Fuse Accessory Feed

Gray-Yellow GY-Y Vehicle Accessory Feed at RUN

E-SERIES TRAILER TOW WIRINGPage 40ELECTRICAL

E-SERIES TRAILER TOW WIRING 2008 MODEL YEAR

Page 41ELECTRICAL

Modified Vehicle Schematic

Hot AtAll Times

4C24-14A411-AEngine Compartment

4C24-14A411-BUnder Dash

4C24-14A411-A

EngineCompartment

4C24-14A411-C

B-Pillar

4C24-14A411-C

B-Pillar

4C24-14A411-B

Under Dash

50A9

*1507 W-R (12)

* Note:Total Shared Current For 1507Circuit Not To Exceed 25 AMPS.

Hot AtAll Times

60 A12

1524 DB (10)

30 A

41

I/P FusePanel

1507 W-R (12) 1507 W-R (12) 1507 W-R(12)

1462 R-W (12)

Hot AtRun / Accy

5 A15

Hot AtAll Times

40 A8

PDBFusePanel

PDBFusePanel

I/PFusePanel

PDBFusePanel

297 BK-LG (10)

295 LB-PK (18)

3258 R-Y (10)

175 BK-Y (12)

4C24-14A411-A

EngineCompartment

4C24-14A411-B

Under Dash

4C24-14A411-C

B-Pillar

F4UB-14A411-B

Rear Frame

49 O (12) 49 O (12) 49 O (12) 49 O (12)

57 BK (18) @ 49 O (12)

TrailerBatteryChargeRelay(PDB)

# 867 DB (12)

# 868 GY-R (12)

Pass-Thru Circuits

@ Note:Total Shared Current For 49Circuit Not To Exceed 25 AMPS.

# Note:Circuits 867 and 868are not fused.

* Note: Total shared current for 1507 circuit not to exceed 25 amps.@ Note: Total shared current for 49 circuit not to exceed 25 amps.# Note: Circuits 867 & 868 are not fused.** Note: Provided in optional vehicle wiring kit.

Instrument Panel & B Pillar

Electric BrakeController Connector

B-PILLAR

Note: Jumper included in optional trailer tow prep kit. (15A416)

Jumper AvailableAt Ford DealerReference4C24-14A348-A

Drivers SideKick Panel

GROUND(BLACK)

FUSED FEED(RED-WHITE)

BATTERY FEED(WHITE-RED)

ING. CONT. FEED(ORANGE)

4C24-14A411-CBROWN CONNECTOR & PIGTAIL ASY.MATES TO CIRCLED CONNECTOR RADIO FEEDSAND POWER FEEDS (EXCEPT RV PREP VANS - GAS - IN KIT)

BATTERY FEED(LIGHT GREEN-YELLOW)

GROUND(BLACK)

F6UB-14335-A (Visor Lamps, Dome Lamps)(RV Prep - In Irvin Ind.Dunnage Box)(Cutaways Get F6UB-14A411-Aon 14A200)

DOME LAMP(BLACK - LIGHT BLUE)

REAR VIEW OF I/P FUSED FEED(YELLOW)(IN LOWER CONNECTOR ONLY)

AUX. SW. RR. CONN(LIGHT GREEN - WHITE)

AUX. SW. MED LO(YELLOW - RED)

AUX. SW. MED HI(DARK BLUE - WHITE) AUX. SW. HI

(RED - WHITE)

I/P LAMP FEED(LIGHT BLUE - RED)

**F4UB-14A411-FGRAY CONNECTOR & PIGTAIL ASY.MATES TO CIRCLED CONNECTORAUXILIARY A/C AND POWER FEEDS

PASS THRU TO ENG(DARK BLUE)

PASS THRU TO ENG(GREY-RED)

LH TURN SIGNAL FEED(LIGHT GREEN-WHITE)

RH TURN SIGNAL FEED(WHITE-LIGHT BLUE) IGN CONT FEED

(ORANGE)


**4C24-14A411-BGREY CONNECTOR & PIGTAIL ASYMATES TO CIRCLED CONNECTORRADIO FEEDS AND POWER FEEDSWITH COURTESY LAMP JUMPER

Frontof

Vehicle

Ground 57 10 BK N/A

Load NameCircuit

NumberWire

GaugeCircuitColor

Max.Cont.

Current

Recommended Wire Length (In Feet) W/O Additional Fusing

Cont.Load

20 GA.

Cont.Load

18 GA.

Cont.Load

16 GA.

Cont.Load

14 GA.

Cont.Load

12 GA.

Cont.Load

10 GA.

Cont.Load8 GA.

LH Turn Signal/Hazard 3 18 LG - W 2.2 A 80 121 196

4C24-14A411-B

Battery Feed *1507 10 W-R 25A 26 42 66Ign. Control Feed @49 12 O 25A 93 148 234Pass Thru (Eng) #867 12 DB 25A NOT FUSEDPass Thru (Eng) #868 12 GY-R 25A NOT FUSED

RH Turn Signal/Hazard 2 18 W - LB 2.2 A 81 122 197.5

4C24-14A411-C

Battery Feed *1507 12 W-R 25A 20 32 51

Ign. Control Feed @49 12 O 25A 91 146 230

Fused Feed 1462 12 R-W 25A 93 150 237

F4UB-14A411-F

I/P Lamp Feed 19 20 LB-R 8A 50 50 50

Fused Feed 884 10 Y-BK 10A (HOT IN LOWER CONNECTOR ONLY) 30 45

Aux. Sw. HI 757 18 R-W 8A (CIRCUIT TO BE USED FOR RELAY GROUND RETURN ONLY)Aux. Sw. Med Lo 752 14 Y-RAux. Sw. Med. HI 751 12 DB-W

Battery Feed 54 16 LG - Y 3.25 A 82 133.5

F6UB-14A411-ADome Lamp

(Switched from 54)53 16 BK - LB 3.25 A 82 133.5

Ground 57 18 BK N/A

Auxiliary Heater A /C S ys tem S chematic

F loor

Defrost

Norm ACMax AC

Off

Mix

Vent

489 P K -B K (18)To

F rontA/C

ModeS witch

Hot At R un

687 G Y-Y (10)

I/PF useP anel

A/C ModeS witch

Hot At All Times

P DBF useP anel

37 Y

884 Y-B K (10)

M

Aux A/CR elay

57 B K (18)

371 P -W (10)Aux B lower

Motor261

Aux HighB lower R elay

753 Y-R (18)

57 B K(10)

515 O-R(12)

753 Y-R (18)

752

Y-R(12)

Aux B lowerMotor R es istor

L M

HOff

AuxiliaryHeater/AC

B lower S witch57 B K (12)

757 R -W (18)

751 DB -W (12)

752 Y-R (12)

O-B K(10)

ToF ront

B lowerMotorR elay(C oil)

753 Y-R (18)

Not Included with Aux. Heator Heat/AC P rep. P ackages 57 J , LIncluded with 57 X

Not Included with Aux. Heator Heat/AC P rep. P ackages57 J , L, X

751

DB -W(12)

15A

13

50A

14

2008 MODEL YEAR

E-SERIES TRAILER LAMP PLUG AND WIRINGPage 42ELECTRICAL

VIEW OF ENGINE COMPARTMENT (L.H. SIDE)

FRONT OFVEHICLE

PASS THRU TO I/P(DARK BLUE)


IGN. CONT. FEED(ORANGE)

PASS THRU TO I/P(GREY-RED)

**4C24-14A411-ABLACK CONNECTOR & PIGTAIL ASYMATES TO CIRCLED CONNECTORTRAILER FEEDS

MODIFIED VEHICLECONNECTOR

TO 4 WABS

* Note: Circuits 867 and 868 are not fused# Note: Total shared current for 49 circuit not to exceed 25 amps.@ Note: Total shared current for 1507 circuit not to exceed 25 amps.** Note: Provided in optional vehicle wiring kit.


Battery FeedIgn Control Feed

Pass Thru (I/P)Pass Thru (I/P)

@1507#49

*867*868

1012

1212

W-RO

DBGY-R

25 AMP25 AMP

25 AMP25 AMP

2895

45152

71240

Load NameCircuit

NumberWire

GaugeCircuitColor

Max.Cont.

Current

Cont.Load

18 GA.

Cont.Load

16 GA.

Cont.Load

14 GA.

Cont.Load

12 GA.

Cont.Load

10 GA.

Cont.Load8 GA.

Rear Chassis Lamp and Trailer Tow Schematic

57 BK(18)

TrailerBack-up

LampRelay(PDB)

12

15A

I/PFusePanel

Hot AtRun

1119 R (10)15

5A

297BK-LG

(10)

Hot At Run/Accy

I/PFusePanel

295LB-PK(18)

TrailerBatteryChargeRelay(PDB)

57BK(18)

8

40A

PDBFusePanel

16

20A

10

30A

TrailerRunningLampsRelay(PDB)

57 BK(18)

ElectricBrake

Controller

Hot At All TimesHot At All Times

10

20A

I/PFusePanel

1052 T-BK (10)

195 T-W (16)

50

(12)

14 BR(12)

To TrailerElectric Brakes

43 DB(12)

To TrailerRunning Lamps

962 BR-W(14)

RelayBlock

(Eng Cmpt)

2W-LB(18)

To TrailerLH Turn/Stop

Lamp

To TrailerBattery and

Modified Vehicle

Dir. Sw.

Rt.Dir.

Lt.Dir.

I/PIndicator

Lamp

RHFront

Turn Lamp

2W-LB(18)

LHPark/Stop/Turn

Lamp

Hi-MountStop Lamp

RHPark/Stop/Turn

Lamp

57BK(18)

57BK(18)

57BK(18)

ToHeadlamp

Switch

14BR(18)

3 LG-W(18)

I/PIndicator

Lamp

LHFront

Turn Lamp

3 LG-W(18)To Trailer

Ground To TrailerRH Turn/Stop

LampTo TrailerBackup Lamps

963 R-Y(14)

206 W(10)

49 O(12)

52Y

(18)

64DG(18)

511 LG (18)

RHBackupLamp

LHBackupLamp

57 BK(18)

57 BK(18)

140 BK-PK (18)

DigitalTRS

1043 DG-Y (14)

296W-PK(18)

175BK-Y(14)

Off

Off OnHazard Switch

298 P-O(18)

11

15A

I/PFusePanel

7

10A

Hot At Run

Hot At All Times

10 LG-R (18)

687 GY-Y(10)

1052T-BK(10)

StopLampSwitch

BSI

569DG(18)

57 BK (18)

294W-LB(16)

10 A

6

I/P Fuse Panel687 GY-Y (10)

HotAt

Run

MultifunctionSwitch

(Steering Column)

10 LG-R (18)

385 W-R(18)

44 LB(18)

57 BK(18)

Turn SignalHazard Flasher

511 LG (18)

9LG-O(18)

5 LB-O (18)

14 BR (18)

On

Aux Battery Relay(With Aux. Battery)

3258 R-Y (10)

3258 R-Y(10)

3258 R-Y(10)

326 W-P(10) 60 A

20

PDBFuse Panel

38 (6)

Hot At AllTimes (BK)

38 (6)

2 - 12 GAFuse Links

Without Aux. Battery

HeadLampSwitch

*

Electric Brake Not Supplied By FordClass I Trailer TowClass II / lll / lV Trailer Tow

57BK(18)

14 BR(18)

3258 R-Y (10)

3258 R-Y(10)

1043DG-Y(14)

1043DG-Y(14)

1043 DG-Y (14)

10 A

39

I/P Fuse Panel

569 DG(18) 569 DG

(18)511 LG (18)

511 LG (18)

26

20A

PDBFusePanel

Hot AtAll Times

1523DG(10)

212 DB (10)

2W-LB(18)

212DB(18)

511LG(18)

9LG-O(18)

212DB(18)

5 LB-O (18)

57BK(18)

57BK(18)

5 LB-O (18)

50R

(12)

R

NR (Not recommended) - Do not use, wire gauge is not intended for this application.For the ground circuit, the length and gauge are dependent on the desired loadand voltage drop.* Note: Total shared current for 49 circuit not to exceed 25 amps.# Note: Total shared current for 962 & 963 circuit not to exceed 18 amps.@Note: 23A is the Max Steady State current at ambient temperature that 18 gauge wire can handle.** Note: Circuits used with rear body/chassis lamp, not compatible with trailer tow.## Note: Circuits used with trailer lamps not included with this kit. Jumper included in optional trailer tow prep kit. (15A416)

Load NameCircuit

NumberWire

GaugeCircuitColor

Max.Cont.

Current


Cont.Load

20 GA.

Cont.Load

18 GA.

Cont.Load

16 GA.

Cont.Load

14 GA.

Cont.Load

12 GA.

Cont.Load

10 GA.

Cont.Load8 GA.

Trailer Tow Battery Feed * 4918

O 2.5 AMP86 129 210Trailer Tow LH Turn ST LP 52 Y

14 23 36

64

12

DG

26 41 65Trailer Tow Running Lamp # 962 14 BN-W

12 BN-LGTrailer Tow Back - Up Lamp

Trailer Tow RH Turn ST LP

# 963

188 AMP8 AMP18 AMP

18 AMP

86 129 21016

34 55 86**9

14LG-O 2 AMPLH Turn ST LP

**5 O-LB**14

14

BR

Ground

**140 18 BK-PK

18 BK

Park LampRH Turn ST LP

**57

182 AMP5 AMP4 AMP

@23 AMP

Back - Up Lamp

8

8NR12

131310

19

19191629

313125

47

48484075

777764

120

LH TURN/STOP LAMP(YELLOW)

GROUND(WHITE)

RH TURN/STOP LAMP(DARK GREEN)

RUNNING LAMP(BROWN-WHITE)

TRAILER BACK-UP(BLACK-LIGHT GREEN)

TRAILER BRAKES(DARK BLUE)

BATTERY(ORANGE)

##F4UB-14A411-BBLACK CONNECTOR & PIGTAIL ASYMATES TO CIRCLED CONNECTORTRAILER FEEDS

##F4UB-14A411-DBROWN CONNECTOR & PIGTAIL ASYMATES TO CIRCLED CONNECTORTRAILER FEEDS

USAGE

VANS / WAGONS REQUIRE: (1) F4UB-14A411-B

CUT-AWAY / STRIPPEDCHASSIS REQUIRE: (1) F4UB-14A411-D

FRONT OFFRAME

FRAME (L.H. REAR)

SELECTEDVANS / WAGONS

CUT-AWAY &STRIPPED CHASSIS

LH TURN/STOP LAMP(LT GREEN-ORANGE)

GROUND(BLACK)

RH TURN/STOP LAMP(ORANGE-LT BLUE)

PARK LAMP(BROWN)

BACKUP LAMP(BLACK-PINK)

**4C24-14A411-DBLACK CONNECTOR & PIGTAIL ASYMATES TO CIRCLED CONNECTORCHASSIS LAMP FEED

2008 MODEL YEAR

E-SERIES TRAILER LAMP PLUG AND WIRINGPage 43ELECTRICAL


SECOND UNIT BODY MOUNTINGE-SERIES CUTAWAY

E-SERIES SUPER DUTY CUTAWAY SUB MOUNTINGSYSTEM

FORD OPTIONAL SPACERS

Ford provides optional SUB mounting spacers whichwill isolate the SUB from the frame. The SUB should beattached to these spacers using all the provided holesin the spacer with a suggested minimum 7/16-14 UNCgrade 8 fastener. These fasteners should be directedaway from any fuel system component or should notextend more than 25.4 mm [1.00 in] below the spacerflange. The location of these spacers is shown on page53-59. The rubber isolators on the spacers are capableof 19.0 mm [0.75 in] movement in spherical zone from astatic (design) position, which is the same for theisolators that mount the Cutaway body to frame. Thiswill minimize squeaks, rattles and water or air leaks atthe mounting surface of the SUB, to Cutaway body. TheFord optional spacers will accommodate therecommended fuel fill neck installation and arecommended 101.6 mm [4.00 in] minimum clearancebetween the frame and the bottom of the SUB (exceptat the rear axle kick-up area).

NON-FORD SPACERS

Vehicles not equipped with the Ford optional spacershave 34.8 mm [1.37 in] diameter holes on the upperflange of the frame sidemembers for body to frameisolators. The density/durometer, size and quantity ofthese isolators should be based on the SUB weight plusthe projected payload of the completed vehicle, withinthe limits of the GAWRs and GVWR, as determined bythe final stage manufacturer.

NO SPACERS

If the final stage manufacturer chooses to attach theSUB (or other components) to the frame by bolting orwelding, the following restrictions are to be followed:1. The frame rail flanges, including the flange bend

radius, must not be drilled or welded upon. Also,flanges may not be cut/trimmed to provideclearance to added hardware or structure.

2. When bolting the SUB (or other components) to theframe, follow the guidelines on the following pages.

Note that hard mounting of the SUB to the frame and tothe cutaway body may result in NVH and cutaway bodydurability issues.

NOTES

E-450 Super Duty Cutaway and Stripped Chassisvehicles have a transmission mounted parking brake.SUB structures should clear this component by 25.4mm [1.00 in] minimum.

[176.00 in] WB vehicles equipped with a 55-gallon fueltank will require a 457 mm [18.00 in] minimum frameextension to provide for an adequate departure angle.

The attachment of the SUB to the Cutaway body shouldconsider the following:1. Blind installation of self- expanding nut type

fasteners can be located in the zone as defined inthe figure on this page, and should allow forfunctional expansion, and be equally spaced. Thebody edge flange may also be used for fastenersprovided the center of the required hole is 1.5 timesthe hole diameter from the edge of the panel.These recommendations apply to both B-pillarattachment.

2. Removal of the access panel and fasteners at thelower area of the B-pillar will allow for flushmounting of the SUB. This opening should becompletely covered and sealed from obviousclimatic conditions.

3. Roof attachments should be equally spaced andare permitted on the flange provided. The center ofthe required holes should be 1.5 times the holediameter from the edge of the flange.

4. Floor attachments should be equally spaced andare permitted on the flange provided. The center ofthe required holes should be 1.5 times the holediameter from the edge of the panel.

5. Washers or doublers should be considered toincrease the bearing surface under fasteners toincrease joint integrity and to decrease sheet metalfatigue, squeaks, and rattles.

6. Gaskets or sealers installed between the Cutawaybody and the SUB should consider thedisplacement and stabilization of such materialswhen clamped, and the effect on joint integrity.

2008 MODEL YEAR

Page 44SECOND UNIT BODY

E-250/350/450 SUPER DUTY STRIPPED CHASSIS SECOND UNIT BODY INSTALLATION

SEC

REAR WHEELCENTERLINE

REARBOLSTER

FRAMESIDERAIL

BOLTATTACHMENT1/2 INCHGRADE 8

BODYCROSSMEMBER

279[11.0]

203[8.0]

FRONTBOLSTER

FRAMESIDERAIL

WELD

VIEW IN CIRCLE

FRONTRADIUSARM

CUT OUT BOLSTERTO CLEARCROSSMEMBERS

BOLTATTACHMENT

TIEBAR

FRONTBOLSTER

RADIATOR COWLSUPPORT STRUCTURE

TIEBAR

DIMENSIONS ARE SUGGESTED AND MAY BE REVISEDAT THE BODY BUILDERS DISCRETION.

REARBOLSTER

121[4.75]

WELD

A

VIEW IN CIRCLE B

Z

VIEW IN CIRCLE C

Z

Z

BB0462

xxxxxxx

NOTE:

REAR BOLSTER

B CA


SECOND UNIT BODY MOUNTINGE-SERIES STRIPPED CHASSIS

E-250/350/450 SUPER DUTY STRIPPED CHASSISSECOND UNIT BODY

A full length structural body should be attached to thechassis utilizing a system of body bolsters bolted andwelded to the chassis frame sidemember as shown onthis page.

Rear body bolsters extend along the parallel sections ofthe frame sidemember using the existing 34.8 mm [1.4in] diameter holes as shown in View B, on this page.

Bolster attachment in the rear axle kick-up area can beaccomplished by bolting shear plates to the web of theframe sidemember as shown in View C, on this page.The maximum size hole that may be drilled in the frameweb is 19 mm [0.75 in] diameter. Refer to the drillingprecautions in the Frame section.

Front body bolsters should be attached to the framesidemember as far forward as possible. They should bewelded to the web of the frame sidememberimmediately to the rear of the front radiator and cowlsupport structure as shown in View A. Front bolstersshould not be bolted to the frame sidemember in thisarea since there is no access to the inside surfacesidemember.

Each front bolster should be rigidly connected to thecorresponding rear bolster through the body floor or atie bar.

Do not weld to the flanges of the side rail. Refer to thewelding precautions in the Frame section.

2008 MODEL YEAR

Page 45SECOND UNIT BODY

DESIGN

DESIGN RECOMMENDATIONS 2008 MODEL YEAR

COOLING SYSTEM1. Equipment such as flashing lights and sirens, spare tires

or any other accessories should not be installed in thegrille area forward of the radiator or air cleaner air inlet.Doing so restricts proper air flow through the radiator andengine compartments. E-Series and Super Duty F-Seriesare illustrated in the figure below.

2. For proper engine cooling, do not alter, change thelocations of, or remove the original equipment fan, fanclutch, or shroud.

3. Maintain a 50/50 mixture of ethylene glycol-basedantifreeze-to-water ratio when adding or modifying theheater system or auxiliary heater system. A 60/40antifreeze-to-water ratio may be necessary during wintermonths in very cold climates. For the remainder of theyear, however, a 50/50 ratio should be maintained.

4. Upper radiator hoses and heater hoses, which are addedor replaces, should be EPDM-Kevlar composition. Lowerradiator hoses should be EPDM-Rayon composition.

5. The radiator and fan shroud should not be used asstructural members and additional components shouldnot be attached.

6. Revisions to the Front End Accessory Drive System mayaffect the cooling system/component performance andare not recommended.

7. Do not alter or modify the automatic transmission coolingsystem.

8. The minimum radiator grille opening (excluding all grilleparts) for the E-Series Stripped Chassis, to provideoptimum cooling for the engine, is 300 sq. in.

9. Equipment, hazardous materials markers, or placardsmust not obstruct the airflow to the radiator or the aircleaner inlet on the E-Series Super Duty StrippedChassis.

10. The E-Series Super Duty Stripped Chassis enginecompartment must be designed to eliminate any aircirculation restriction that would affect the air induction orcooling systems. An engine compartment must provideadequate flow-through ventilation to prevent local airtemperature from exceeding recommended maximums.

CLIMATE CONTROL SYSTEM1. An Auxiliary Heater A/C Connector Package can be either

standard or optional on E-Series vehicles for connectingauxiliary climate control systems to the Ford system. Thefollowing items are important for the maximum efficiencyof the combined systems:• The connector tubes are under the floor directly below

the driver’s seat.• The heater supply tube is identified with a white paint

dot and should be connected to the lowest connectionport on the auxiliary heater core.

• The A/C connector tubes have a 20 x 1.5-6g metricthread for high pressure and 24 x 2.0-6g metric threadfor low pressure.

• If the vehicle is equipped with the auxiliary heater-airconditioner, do not operate the front A/C system prior tothe addition of an auxiliary system. The system oil couldsettle in the connector tubes and not provide lubricationto the compressor. See Bulletin Q-47. To obtain a copy,log on to www.fleet.ford.com/truckbbas/ and select fromthe “Bulletins” tab.

• The Ford provided auxiliary blower switch requires anelectric relay for high-speed blower operation. Additionaldetailed information is available in Bulletin Q-19. Toobtain a copy, log on to www.fleet.ford.com/truckbbas/and select from the “Bulletins” tab.

2. R-134a charge A/C systems must use PAG-type lubricatingoil YN-12-D, Ford part number F2AZ-19577-AD. Always usethe same refrigerant and lubricating oil as originally equippedby Ford Motor Company.

3. Maintain a 4% suspended oil ratio in the A/C system forproper compressor lubrication.

4. E-Series A/C and Refrigerant Oil System are classifiedinto the following types:

A label stating the total refrigerant charge, type ofrefrigerant (R-134a), and type of compressor lubricant oil(PAG) used must be affixed in a conspicuous place in theengine compartment.

5. The A/C compressor will cycle during the defrost mode. Arefrigerant shut-off valve for the auxiliary system mayimpair compressor lubrication.

6. R-134a charged A/C systems should use barrier type A/Chose. Barbed fittings and external clamping may not becompatible with this type of hose. Swaged, permanentfittings on this type of hose are recommended.

7. NEVER ATTACH ANY COMPONENT TO THETRANSMISSION FILLER AND DIPSTICK TUBE.

8. Auxiliary heater and air conditioning systems hoseroutings must consider the following:• Dynamic engine roll or any system component which

has an operating zone. Make sure there is adequateclearance (e.g., transmission downshift linkage,steering column shift linkage).

• Do not route heater or A/C hoses directly over or nearthe exhaust system.

• Do not route hoses by attaching to the engine.• Use only metallic “Y” and “T” type fittings or OEM

approved materials.• Do not route hose in wheelhouse area.• Do not route by sharp edges or moving

component parts. There must be shield protectionfrom any potential abrasive source.

• When routing in stone kickup area, lines should beprotected by shields. Minimize use of concentricprotective heater hose shields. Limit length of concentrichose shields to 305 mm [12 in] maximum.

9. For additional information, refer to Bulletin Q-148, “AirConditioning and Front End Accessory Drive (FEAD) DesignBest Practices - E-Series and F-Series”, available atwww.fleet.ford.com/truckbbas under the “Bulletins” tab.

10. Front End Air Flow:• There should be nothing mounted in front of nor behind the

front end grille opening which could reduce the effective airflow to the cooling module.

• Under no circumstances should there be anymodifications to the fan shroud or stator.

• Do not modify or remove any seals which are part of thecooling module (e.g., body seals, condenser seals,radiator seals, snow shield).

11. Vehicles ordered with Auxiliary A/C Prep Packages:• When attaching an aftermarket Auxiliary A/C unit to an

existing OEM front A/C system, the Auxiliary A/C unitmust use a Thermal Expansion Valve (TXV) - a ClutchCycling Orifice Tube (CCOT) cannot be used.

• Compressor discharge gas temperature should notexceed 130°C [266°F] under any driving or idleconditions.

E-SERIES STRIP CHASSIS A/C PREP PACKAGE1. The E-350/450 chassis cab comes with a R-134a (non-

CFC) A/C Prep Package. The package consists of acompressor, condenser, front CCOT HVAC assembly,accumulator, FEAD, and connection points for a TXV-Controlled Auxiliary A/C unit.

2. Information on determining air conditioning refrigerantand lubricant quantities are outlined in the Ford TruckQuality Program Guidelines on the web site http://www.fleet.ford/com/truckbbas/topics/guidebook.html

EngineVehicle

ConfigurationR-134a

(oz)R-134a

(lb)Total PAG

Oil (oz)

GA

S

Front Only 30 1.88 8

Front & AUX 54 3.38 16

Front w/Prep Pack 30 1.88 8

DIE

SE

L Front Only 36 2.25 7

Front & AUX 54 3.38 11

Front w/Prep Pac 36 2.25 7

BOTTOM VIEW SHOWNBB0247

FIGURE B - DO NOT APPLY UNDERCOATING IN SHADED AREA

BB0483

SHIELD CONFIGURATION MAY VARY WITHVEHICLE TYPE OR ENGINE SELECTION

FRONT OFVEHICLE

FIGURE A - UNDERBODY MOUNTED HEAT SHIELDS FOR VANS

BB0484

ENGINECOVER

SEAL(RUBBER)

CARPETENGINE COVERINSULATION

FLOOR PAN

TYPICAL SECTIONCARPETING INSTALLATIONAT ENGINE COVER INSULATION

FIGURE C - E-SERIES ENGINE COVER SEAL

DESIGN RECOMMENDATIONS

EXHAUST SYSTEM

1. Do not substitute exhaust system components oradd to those furnished by Ford, except as noted inthis section. Such a substitution or addition mayadversely affect engine performance or emissionssystem effectiveness.

2. Do not change the position or routing of theexhaust system components. Such a change mayaffect the amount of heat transferred to body,chassis, or powertrain components, particularly fuelsystem components. Specifically, do not add dualexhausts or reroute exhaust components to the leftside of the vehicle.

3. Do not remove or modify the existing shields. Fordunderbody heat shields are installed on vehicles toprovide heat protection for the vehicle floor andbody mounting system, and must remain in placeon the completed vehicle. (See Figure A.)

4. Exhaust heat shields should be added by a bodybuilder, and should extend far enough beyond theexhaust system components to protect underbodysurfaces from heat radiated at any angle. Addshields over the muffler and exhaust pipe kick-upareas.

5. Do not remove Ford furnished exhaust clamps andhangers.

6. An additional exhaust hanger should be installed, ifappropriate, to support extended tailpipe lengthnecessitated by body dimensions.

7. Do not make a rigid connection between theexhaust system and the body.

8. Do not apply body undercoating on the fuel tank,fuel fill hose, or fuel fill vent hoses. The extrainsulation on these components may causeexcessive heat build-up or possible materialincompatibility concerns. (See Figure B.)

9. Do not apply body undercoating within twelveinches of the are directly above the exhaust, on anycomponents within twelve inches of the exhaust, orto any part of any exhaust system. Undercoatingwill smoke or burn if subjected to high heat. (SeeFigure B.)

10. Extensions to the exhaust outlet pipe should directexhaust away from the body to minimize thepossibility of fumes entering the vehicle. Extensionsshould also protrude beyond the vertical bodysurface.

11. Install all underbody plumbing for heaters, airconditioners, and other accessories so that theyare not installed against sharp surfaces or jaggededges. Protect from exhaust heat when routing.

12. Use only stainless steel for any exhaust systemmodifications or additions.

13. Exhaust system revisions should consider thermalexpansion of materials and the affect on designclearances.

FORD BODY COMPONENTS1. Modifications to doors, roof, or body side panels

may have an affect on F/CMVSS 208, 210, 212,214, 219, and 301 compliance. Refer to theStatements of Conformity section in the IncompleteVehicle Manual for compliance representations.

2. Running boards or entry steps should use amounting system that will attach only to the body.The Ford body to frame isolators allow bodymovement which may loosen fasteners. Acombined frame and body mounting system maycause frame Noise, Vibration, and Harshness(NVH) transfer through such a mounting systeminto the body.

3. Use a butyl type sealer on trimmed body sheetmetal panels to prevent corrosion.

4. Temporary mounting pads may eliminate chippingand scratches when accessories are installed.

5. Select materials which will not have a corrosiveaction with each other.

6. Additional fresh air vents should be located so thatengine exhaust cannot be drawn into the vehicle.

7. When adding holes to the floor of the vehicle,consideration must be given to all componentsbelow the floor. The use of drill stops isrecommended.

8. Fasteners added to the floor should not point at thefuel tank or should have an appropriate shield.Components with sharp edges should have anappropriate shield to eliminate the possibility of fueltank penetration in crash situations.

9. Components added to the E-Series engine covershould allow for easy removal. Refer to theStatements of Conformity in the Incomplete VehicleManual for Occupant Protection Zone requirementsfor the engine cover and other affected areas.

10. The E-Series engine cover seal requires thatcarpeting and insulation should be installed asshown in Figure C.

11. Power operated windows, a partition, or roof panelsystems when added to a vehicle with a GVWR of4536 [10,000 lb] or less must comply with therequirements of F/CMVSS 118, refer to theStatements of Conformity in the Incomplete VehicleManual.

12. When a Second Unit Body (SUB) or rear closurepanel is attached directly to the cutaway body,difficulty may be experienced when closing doorsdue to air pressure build up. It is recommended thatvent(s) be installed which will allow “ONE WAY”pressure release from the inside of the cab to theoutside. Recommended minimum size of theventing is 36 square inches.

WARNING:

VEHICLE OPERATING TEMPERATURES

SOME TRUCKS OF FORD MOTOR COMPANY MAYEXHIBIT H IGH ENGINE COMPARTMENT ANDEXHAUST SYSTEM TEMPERATURES IN CERTAINOPERATING MODES. COMPONENTS, INCLUDINGEXHAUST HEAT SHIELDING SYSTEMS, HAVE BEENINSTALLED AS STANDARD EQUIPMENT ON SOMEVEHICLES IN OUR ASSEMBLY PLANTS IN AN EFFORTTO PROVIDE THERMAL PROTECTION AGAINST SUCHTEMPERATURES. AFTERMARKET EQUIPMENTINSTALLERS OR INTERMEDIATE AND FINAL STAGEMANUFACTURERS ARE RESPONSIBLE FORPROVIDING THERMAL PROTECTION (e .g . ,UNDERBODY HEAT SHIELDS) FOR ANY STRUCTUREOR EQUIPMENT ADDED TO THE VEHICLE ANDSHOULD NOT REMOVE ANY COMPONENTS OREXHAUST HEAT SHIELDING INSTALLED ON THEVEHICLE BY FORD.

2008 MODEL YEAR

Page 47DESIGN

WHEELS AND TIRES

1. Use only wheels with the same load capacity, rimwidth, rim offset, and mounting configuration asthose originally installed on the vehicle. Consult anauthorized Ford dealer for correct wheel loadcapacity, size, and usage. Wheels used mustconform to the F/CMVSS 120. The use of anywheel or tire, other than those originally installed onthe vehicle as manufactured by Ford, mayadversely affect load carrying capacity, handling,bearing life, ride, braking performance,speedometer/odometer accuracy, automatictransmission shift timing, and tire/wheel clearanceof the body and chassis.

2. Use only replacement tires that are the same size,load index, speed rating and type (such as P-metricversus LT-metric or all season versus all-terrain) asthose originally provided by Ford. Therecommended tire and wheel size may be found oneither the Safety Compliance Certification Label orthe Tire Label which is located on the B-pillar oredge of the driver’s door. If this information is notfound on these labels, consult a Ford dealer. Use ofany tire or wheel not recommended by Ford canaffect the safety and performance of the vehicle,which could result in an increased risk of loss ofvehicle control, vehicle rollover, personal injury anddeath. Additionally, the use of non-recommendedtires and wheels could cause steering, suspension,axle or transfer case/power transfer unit failure. Ifyou have questions regarding tire replacement,contact an authorized Ford dealer. Tires used mustconform to FMVSS 119 (New Pneumatic Tires for

Motor Vehicles) and FMVSS 139 (New PneumaticRadial Tires for Light Vehicles) in the United States,or to the Motor Vehicle Tire Safety Regulations inCanada.

3. SRW vehicles must comply with FMVSS 138 (TirePressure Monitoring Systems). Reference the TirePressure Monitoring System (TPMS) section inOwner Guide & Workshop Manual.

4. SRW vehicles must comply with FMVSS 138 (TirePressure Monitoring Systems). Reference TirePressure Monitoring System (TPMS) section inOwner Guide, Workshop Manual & FMVSS 139(New Pneumatic Tires for Light Vehicles).

5. If you loosen or remove wheel lug nuts for anyreason or have in your possession a vehicle at anyof the mileage intervals listed in the Wheel Lug NutTable below; check the lug nut torque and re-torqueto the specifications as listed in the table. Follow therecommended Maintenance Procedure.

SUSPENSION AND STEERING SYSTEMNOTICE – VEHICLE HANDLING INFORMATION

The weight of the body structure and its center of gravitylocation (both longitudinally and vertically), as well asthe weight and positioning of the cargo load, areimportant to the handling of the completed vehicle.Subsequent stage manufactures should note thatmatching a body to a chassis in a manner appropriatefor the intended use of the vehicle is the responsibility ofthe final-stage manufacturer. Following therepresentations in this book or the IVM Manual, withrespect to center of gravity locations and body weightsfor compliance with Federal or Canada Motor Vehicle

Safety Standards, is only part of the task of producing acompleted vehicle that handles appropriately in service.

1. Front end alignment warranty policy for incompletevehicles is based upon the completed vehicleremaining within OEM weight ratings, vehicleattitude, suspension and wheel/tire guidelines, andother characteristics affecting wheel alignment.Exceeding or modifying these restrictions mayjeopardize related warranty.

2. Modifications made by subsequent stagemanufacturers, particularly those that significantlyaffect vehicle ride heights, may cause vehiclecontrol problems during excessively sharp turns orother abrupt steering maneuvers, possibly leadingto rollover or other accidents that could result indeath or serious injury.

The steering gear, intermediate shaft, coupling shaft,linkage, column, and steering wheel should not bealtered or relocated. Steering linkage travel should notbe restricted.

3. Ford front and rear GAWRs and GVWR must not beexceeded.

4. Front or rear suspension components should not bedrilled, cut, welded, or relocated for any reason.

5. Welding to the frame in the steering gear area is notrecommended.

6. If rear suspension spacers are used between thespring and axle seats to accommodate side-to-sidevariations, they should not exceed 3/8 inch. Thespacers should not exceed the profile of the axlespring seat. Additional spacing may adversely affectdriveline angles and axle system packageclearance. Also affected are spring stress limitsfrom excessive jounce travel.

7. Do not use any suspension component as awelding ground.

8. When welding or cutting near suspensioncomponents, shield and protect all springs andrubber components from heat penetration andwelding splatter.

9. Any add-on device mounted on the steeringcolumn, shroud, multifunction switch, or gearselector lever, must not affect steering columnangles, tilt mechanism (if so equipped), range ofoperation, or steering column mounting hardware.Any such device must not interfere with steeringcolumn collapse stroke travel during crashsituations or air bag deployment.

10. Vehicles equipped with an air suspension systemmust verify that the settings are correct once thevehicle is completed by the final stagemanufacturer. Refer to the applicable Ford truck

workshop service manual for the completeprocedure.

ENGINE1. Refer to the Emission Control Modifications on

Safety/Emission pages prior to makingmodifications to any engine component that couldaffect the emission certification.

2. The engine should not be operated with the hoodup or removed. This may allow excessive unforcedair to circulate that could adversely affect thecooling system.

3. Do not use manual throttle kickers4. When using electric throttle kickers on gasoline

engines, set the high idle RPM at as low as possibleto obtain the required performance. The idle speedmust be set when the engine is at normal operatingtemperature and under normal load. This RPMsetting should be affixed to the vehicle and shouldbe checked after the 2,000 mile brake-in enginetune up. This information should be provided to thepurchasers. The addition of throttle kickers mayaffect electronic transmission operation.

5. An auxiliary crankshaft bearing support is requiredon all modular gas engines before a FEAD-mounted PTO can be installed. Refer to PowerTake-Off Installations page for information.

6. Do not tap into the electrical circuits attached to theAccelerator Pedal Position Sensor (APP) on theaccelerator control. Do not bypass the electricalcircuits attached to the APP. See figure below forcomponent identification.

7. Installation of a gasoline engine speed governor ispermissible, provided the governor design iscompatible with each respective throttle body forthe individual engine application and it does notexceed specified engine maximum RPM. It mustalso meet all noise and engine emissionrequirements. Governor installations may affectelectronically controlled transmissions. ContactFord Truck Body Builders Advisory Service beforeinstalling.

WHEEL LUG NUT TABLE

MILEAGE WHEEL LUG NUT TORQUE

VEHICLE TYPE KM MILES Nm Ft LbE-SeriesE-150/250/350 SRW 800 500 203 150

E-350/450 DRW160 100

190 140800 500

F-SeriesSuper DutyF-250/350 SRW 800 500 203 150Super DutyF-350/450/550 DRW

160 100203 150

800 500

WARNING:

SOME AFTERMARKET WHEEL ASSEMBLIES MAY NOT BECOMPATIBLE WITH SOME VEHICLES AND SHOULD NOTBE USED. USE OF INCOMPATIBLE WHEEL ASSEMBLIESMAY RESULT IN WHEEL FRACTURES, SEPARATION, WITHTHE POTENTIAL FOR AN ACCIDENT, AND INJURY TOOCCUPANTS. FORD RECOMMENDS THAT ONLY WHEELASSEMBLIES APPROVED AND RELEASED BY FORDMOTOR COMPANY FOR THE VEHICLE MODEL SHOULDBE USED.

IMPORTANT:The final-stage manufacturer is responsible for verifyingthat the front wheel toe is within Ford specifications oncompleted vehicles. The steering wheel clear vision(horizontal or level orientation of the steering wheel)should also be maintained when resetting wheel toe.These specifications are found in the GeneralSuspension section of the Ford Shop Manual.

2008 MODEL YEAR

DESIGN RECOMMENDATIONSPage 48DESIGN

WARNING:

RE-TORQUE ALL LUG NUTS TO SPECIFICATION. IT ISIMPERATIVE THAT THE DEALER RETORQUE ALL WHEELLUG NUTS ON ALL VEHICLES PRIOR TO DELIVERY TOTHE FINAL VEHICLE PURCHASER. DUAL REAR WHEELVEHICLES MAY BE SHIPPED WITH THE OUTER REARWHEELS REMOVED AND, THEREFORE, THE DEALERMUST ENSURE THAT THE LUG NUTS ARE RETORQUEDTO THE PROPER SPECIFICATION BEFORE THE VEHICLEIS DELIVERED TO THE FINAL VEHICLE PURCHASER.IMPROPERLY TIGHTENED LUG NUTS COULD LOOSENAND ALLOW THE WHEEL TO COME OFF WHILE THEVEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL.

DESIGN RECOMMENDATION 2008 MODEL YEAR

DRIVELINE

1. Bulletin Q-14, “Guidelines for Modifying TruckDrivelines,” is available on www.fleet.ford.com/truckbbas/. Any deviation from Ford specificationsmay adversely affect powertrain system operationincluding engine and transmission, or componentreliability. Subsequent stage manufacturers orinstallers are responsible to maintain Fordspecifications in the completion of suchmodifications.

2. Rear axle vent and hose, if installed, must not bebent, pinched, or obstructed so that normal“breathing” of the rear axle is provided.

3. On all rear axle assemblies, additional bracket barsor supports must not be welded to the axleassembly. Attachment of any equalizing-type trailerhitch or auxiliary suspension systems (springs)must not be attached to the rear axle assembly.

TRANSMISSION

1. The transmission oil filler tube and dipstick must notbe altered by bending, lengthening, or shortening,and must be readily accessible in the enginecompartment for checking lubricant level. NEVERATTACH ANY COMPONENT TO THETRANSMISSION FILLER AND DIPSTICK TUBE.

2. The installed engine angle must not be altered. Therelative position of engine and transmission to shiftlinkage must not be altered.

3. Transmission vent must not be altered, pinched, orcollapsed, and the vent opening must not berestricted or relocated.

4. Adequate tool clearance and suitable accessopenings for transmission adjustments must beprovided. Transmission removal provisions mustalso be considered.

5. Transmission oil cooler lines should not be kinked,bent, or restricted. All oil cooler lines must beproperly retained with adequate clips. The trucktype external oil cooler must not be “boxed in”,which would restrict adequate air circulation. Useonly Ford factory coolers.

Some automatic transmissions are equipped with“Stand Alone” transmissions fluid coolers. Vehiclesequipped with this new oil to air cooler (OTA) may nothave a transmission fluid cooler in the radiator. The OTAis located in front of the radiator and will requirereplacement every time the transmission is reworked orreplaced. The cooler lines and Cooler Bypass Valve(CBV) must also be cleaned and backflushed.

CAUTION:FAILURE TO REPLACE THE OTA, BACKFLUSH THECOOLER LINES AND CBV MAY RESULT INTRANSMISSION ASSEMBLY INTERNAL DAMAGE.

6. Transmission shift cable, transmission outer shiftlever, and shift cable bracket must not be alteredand must have provisions for adjusting toolclearance. A severe duty shift cable (booted) isavailable as a service part from a Ford Dealer, forSuper Duty F-Series vehicles which experienceextensive off-road use.

7. Some automatic transmissions may be equippedwith a transmission cooler bypass system. Thepurpose of the cooler bypass valve is to allow sometransmission fluid to bypass the transmission fluidcoolers and return to the transmission sump duringcold weather operation. This provides a fastertransmission fluid warm up and increased lube flowduring cold weather operation. Do not remove ormodify this system or transmission damage mayoccur. Do not use the cooler bypass line as a fittingpoint. Vehicles equipped with transmission coolerbypass will NOT have a hot water feed circuit fromthe water pump to the radiator tank containing thetransmission cooler.

CAUTION:DO NOT USE THE COOLER BYPASS VALVE (CBV)AS A HANDLE. DAMAGE TO THE CBV ANDTRANSMISSION MAY RESULT. THIS ALSO CAUSESLEAKS.

8. Transmission service identification tags must not beremoved or destroyed. If the transmission isreworked or replaced, the tag should be attached tonew transmission.

9. Electronically controlled automatic transmissionwire harness routing location, wire harness locatingclips, all heat shielding, and clearance to theexhaust must be maintained as installed from theassembly plant.

10. The manual transmission filler plug should not beobstructed, preventing easy checking of lube levelor filling.

11. Body structures should not be less than 1.00 inchfrom the rectangular vent holes on the top surfaceof the manual transmission housing.

12. Bulletin Q-14 and Q-18 contain additional detailedinformation on modifications which may affecttransmissions. To obtain a copy, log on towww.fleet.ford.com/truckbbas/ and select from thelist of bulletins.

FRAME1. Holes that would weaken the frame sidemember

should not be drilled in the frame. Holes are not tobe drilled in the sidemember’s top or bottom flange.

2. Holes to mount brackets, out-riggers, and supports,may be drilled in the vertical frame side rail webwith the following restrictions:

• Material between edge of hole and inside ofupper or lower flange must not be less than1.50 inch for low carbon steel (36,000 PSI yield).

• The minimum edge distance between any twoholes up to 0.625 inch diameter must be 1.00inch. For larger than 0.625 inch diameter holes,the minimum edge distance must be 1.5 timesthe diameter of the largest hole.

• 0.75 inch is maximum hole diameter.

• Avoid close vertical succession of fasteners.

• All attaching fasteners, including flat washers,must be of high strength steel (Grade 8).

3. When welding is performed anywhere on the vehi-cle, precautionary measures should be taken toprevent damage to electrical system wiring or com-ponents. Prior to welding, any parts which could bedamaged by excessive temperatures should beremoved or adequately shielded. Also, prior towelding, disconnect both batteries, and the PCM.The welding ground clamp should be positioned asclose to the affected welding area as possible.Computer processors should be removed if weldingis to be done within their close proximity. Weldingcables should never be allowed to lay on, near, oracross any electrical wiring or electronic componentduring welding. After welding, when parts are cool,carefully inspect wiring and electrical componentsfor shorts or other damage which could draw exces-sive currents and possibly cause an electrical sys-tem short when the battery is reconnected.

4. Do not weld on frame flanges, including the bendradii.

5. When welding low carbon steel side rails (36,000PSI yield strength), emphasis should be placedupon weld application techniques to avoid stressrisers that may adversely affect frame operatingstresses. When welding within 4 inches of anycrossmember or suspension rivets, remove therivets and replace with Grade 8 bolts and nuts.

6. Do not modify or alter the convoluted framesections in the area behind the front bumper.Modifications or alterations could have an adverseeffect on vehicle performance in a crash situation.

7. Wheelbase alteration and frame extensionguidelines for E-Series Super Duty Cutaway areavailable in Bulletin Q-18 and for F-650/750 & LCFin Bulletin Q-140. Log on to www.fleet.ford.com/truckbbas/ and select from the list of bulletins. Anydeviation from the original vehicle specification willbecome the responsibility of the subsequent stagemanufacturer or installer. This may affecttransmission operation and durability.

8. Recommend the use of OEM front tow hooks only.See Ford Towing Manual FCS-12141-00 for towinginstructions.

9. To prevent collapse of the frame side rail flanges,when U-bolts are used for the attachment of bodiesto the truck chassis, vertical spacer bars must beused between the upper and lower flanges at eachU-bolt.

10. All E-Series Super Duty Cutaways or StrippedChassis with a 176-inch WB and equipped with a55-gallon fuel tank will require an 18-inch minimumframe extension to provide for an adequatedeparture angle fuel tank clearance.

11. School bus rear bumpers should meet the followingrecommended minimum specifications; height,203.2 [8.00] under 10,000 lbs and 241.3 [9.50] over10,000 lbs; 50.8 [2.00] upper and lower flange;304.8 [12.00] wrap-around; 4.8 [.187] thick. See theIncomplete Vehicle Manual for additionalinformation.

JACK

1. Jacks, if installed, must be stowed in an adequatelocation for customer access.

Page 49DESIGN

AMBULANCE BUILDER GUIDELINES

INFORMATION

Ford urges careful consideration of therecommendations that follow. They are based onanalyses of component and vehicle tests, actual servicesituations, and engineering judgments. Disregard ofthese recommendations may affect the durability,reliability, handling and performance characteristics of acompleted vehicle and may elevate underbodytemperatures and increase the potential for fire, or mayaffect the safety of the occupants in the event of anaccident.

These recommendations are supplemental to U.S. andCanadian Motor Vehicle Safety compliancerepresentations provided in the Incomplete VehicleManual. Additional information is also provided in thisbook and Ford Truck Shop Manual which may be helpfulto subsequent stage manufacturers.

Subsequent stage manufacturers are encouraged tocontact the Ford Truck Body Builder Advisory Service ifthey have any questions concerning theserecommendations.

GUIDELINES

1. All Exhaust System and Underbody Heat Managementstatements System and Underbody Heat Managementstatements in the SECOND UNIT BODY MOUNTINGand DESIGN RECOMMENDATIONS sections apply tocompleted ambulance type vehicles.

2. Data concerning the effect of hood louvers isinconclusive. If a body builder chooses to addthem, the opening should be directed rearward toavoid recirculating discharged hot air through theradiator.

NOTE: The vehicle interior vent air enters thepassenger compartment at the base of thewindshield. Louvers may direct heated air orfumes toward this opening. Removal of theunderhood insulation may affect Exterior Noisecompliance. See the Exterior Noise informationon Safety/Emissions.

3. To deal with higher electrical loads, Ford vehicleswith the Ambulance Prep Package are equippedwith dual alternators, dual batteries and heavy dutywiring to handle higher electrical loads. Addedwiring should be of sufficient capacity to handle thehigher current. The alternator should not bemodified, altered or replaced.

4. Added Second Unit Body vents, especiallypowered vents, should be located away from thefuel filler, fuel venting areas and exhaust to avoidfuel fumes and vapors entering the interior of thevehicle.

5. Equipment such as flashing lights and sirens, sparetire, or any other accessories should not beinstalled in the grille area forward of the radiator orair cleaner air inlet. Doing so restricts proper airflowthrough the radiator and engine compartment.Lights, speakers, or sirens should not be mountedin the center area of the grille. Equipment should bemounted as far outboard as possible, not to exceed90 square inches each or 180 square inchescombined in area.

6. An ambulance is not to be used as a tow vehicle.

A FORD VEHICLE IS SUITABLE FOR MANUFACTUREINTO AN AMBULANCE ONLY IF EQUIPPED WITH AFORD AMBULANCE PREPARATION PACKAGE. FORDURGES AMBULANCE MANUFACTURERS TOFOLLOW THE RECOMMENDATIONS FURNISHED INTHE INCOMPLETE VEHICLE MANUAL (AND ANYPERTINENT SUPPLEMENTS) AND THE QUALIFIEDVEHICLE MODIFIER (QVM) GUIDELINES.

USING A FORD VEHICLE WITHOUT THE FORDAMBULANCE PREPARATION PACKAGE TOPRODUCE AN AMBULANCE VOIDS THE FORDWARRANTY AND COULD RESULT IN ELEVATEDUNDERBODY TEMPERATURES, FUEL OVER-PRESSURIZATION AND THE RISK OF FUELEXPULSION AND FIRES.

VEHICLES EQUIPPED WITH FORD AMBULANCEPREPARATION PACKAGES HAVE LABELS LOCATEDON (THE INSIDE) DRIVER DOOR LOCK PILLAR THATSTATE THAT THE VEHICLE IS SO EQUIPPED.

2008 MODEL YEAR

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2008 E-Series (Technical Data Only)

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