2003 F-Super Duty Class A Motorhome Chassis Incomplete Vehicle ...

Incomplete Vehicle TypesFor This Manual

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

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��F-SUPER DUTY

Class A Motorhome ChassisINCOMPLETE VEHICLE MANUAL

May, 2002 3C34–19A268–AA

F 53Basic Stripped

Chassis

Standard Bus (1)Number Title of Standard (Not School Bus) MPV Equip

101 Control Location, Identtification and Illumination X X102 Transmission Shift Lever Sequence, Starter Interlock &

Transmission Braking Effect X X103 Windshield Defrosting & Defogging System X X104 Windshield Wiping and Wasing Systems X105 Hydraulic Brake System X X106 Brake Hoses X X X108 Lamps Reflective Devices & Associated Equipment X X X

108.1 Alternative Requirements for Headlamps X X111 Rearview Mirrors X X113 Hood Latch Systems X X115 Vehicle Identification Number116 Hydraulic Brake Fluids X X X

119(7) New Pneumatic Tires for Vehicles Other Than Passgenger Cars X120 Tire Selection and Rims for Motor Vehicles Other Than

Passenger Cars X(5) X(5) X124 Accelerator Control Systems X X201 Occupant Protection X X205 Glazing Materials X X X206 Door Locks and Door Retention Components X207 Seating System X X208 Occupant Crash Protection X X(3)(4) X209 Seat Belt Assemblies X X X210 Seat Belt Assembly Anchorages X X213 Child Restraint Systems X X X

213.4 Built-In Child Restraint System & Built-In Booster Cushions X X217 Bus Window Retention and Release X225 Child Restraint Anchorage Systems X(6) X(6)

301.1 LPG Fuel Systems X X301.2 CNG Fuel Systems X X302 Flammability of Interior Materials X X

PART Vechicle Identification Number565 (Applicable to incomplete vehicles as well) X X

1106 Noise Emissions X X

U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS(APPLICATION BY VEHICLE TYPE)

FMVSS 107 and FMVSS 211 have been rescinded by NHTSA.FMVSS 112 has been rescinded by NHTSA and the requirements transferred to FMVSS 108.FMVSS 115 requirements transferred to Part 565.

(1) Applicable to Equipment for use on applicable vehicle types.(2) Applicable to Equipment used on MPVs only.(3) Injury criteria applicable to vehicles with GVWR of 3855 kg [8,500 lb] or less and an unloaded vehice weight of 2495 kg [5,500 lb] or

less.(4) Injury criteria is optional on Walk-in Van-Type Trucks, Motor Homes, vehicles manufactured for operation by persons with

disabilities etc. See 49 CFR, Part 571.208, S4.2.2. In Canada, injury criteria is only optional for a vehicle manufactured for operationby persons with disabilities.

(5) The tire and rim information requirements of Standard 120 will be met when the Incomplete Vehicle Label is affixed to the driver-door. This label is shipped with this manual in the plastic bag.

(6)Tether anchors and latch/ISO Fix lower anchors that are installed voluntarily or by regulation must comply with this Standard.(7)Canadian 119 requirements are found in the Motor Vehicle Tire Safety Standards.

1

IMPORTANT:

UNITED STATES AND CANADIAN VEHICLES

Alterations to a stripped chassis or an incomplete vehicle by someone other thanFord Motor Company, or damage in transit, may affect compliance statements thatare furnished in this manual, or representations that are printed on the label thatmay be affixed to a stripped chassis cab vehicle.

INTRODUCTION

Information in this manual is furnished pursuant to United States and Canadian safetyregulations or, in some cases where the information is not required by regulation, is furnishedfor the convenience of intermediate or final stage vehicle manufacturers. Incomplete vehiclesmanufactured for sale or importation into the U.S., are specially equipped for the UnitedStates. The descriptions and statements contained in the manual relate only to motor vehiclesafety standards issued under the National Traffic and Motor Vehicle Safety Act of 1966 asamended.

An incomplete vehicle manufactured for sale or importation into Canada is speciallyequipped for Canada. This vehicle conforms to the applicable Canadian Motor VehicleSafety Standards (CMVSS) on the date of manufacture printed on the cover of this manual.Requirements unique to vehicles for use in Canada are identified in the Statements ofConformity and the Canadian Vehicles section of the manual, page 18.

The “Emission Certification Information” section of this manual contains informationregarding conformity to exhaust emission regulations of the United States, Canada, andthe State of California and fuel economy regulations of the United States.

This manual should not be relied upon with respect to compliance with any regulation ofthe Federal Highway Administration or regulations issued pursuant to the OccupationalSafety and Health Act (OSHA) or any other federal, state, or local regulations governingthe performance or construction of motor vehicles (except for those requirements shownunder the heading “Unleaded Gasoline Label,” page 13, “Warranty and Maintenance,”page 13, “Emission Control Information Label,” page 14).

IMPORTANT:

UNITED STATES VEHICLES

Ford Motor Company has endeavored, whenever possible, to state the specificconditions under which an incomplete vehicle may be completed to conform witheach applicable Federal Motor Vehicle Safety Standard. These specific statementsare intended to aid subsequent stage manufacturers in avoiding instances ofinadvertent noncompliance to particular standards.

Note that the final responsibility for the compliance of the completed vehicle restswith the final stage manufacturer who is required by law to certify, as prescribed bySection 567.5 of Title 49, Code of Federal Regulations, that the completed vehicleconforms to all applicable Federal Motor Vehicle Safety Standards and that allapplicable federal, state and California emission/noise standards are conformedwith.

Ford Motor Company does not make any representation as to the appropriatenessof modifications for any particular application other than expressly stated herein.Intermediate and final stage manufacturers must exercise proper engineeringjudgment to determine if a modification is appropriate for their specific application.

INTRODUCTION

2

INTRODUCTION ....................................................................... 1

GENERAL INFORMATION ........................................................ 3

VEHICLE DESCRIPTION .......................................................... 5

DEFINITIONS ............................................................................. 6-7

STATEMENTS OF CONFORMITY ............................................. 8-12

UNITED STATES VEHICLESEmission Certification Information ......................................... 13Emission Control Hardward .................................................. 13High Altitude Requirements .................................................. 13Unleaded Gasoline Label ..................................................... 13Exterior Nosie ........................................................................ 13Tampering With Noise Controls ............................................. 13Warranty and Maintenance ................................................... 13Evaporative Emissions .......................................................... 13Check Engine - Warning Light ............................................... 14Vehicle Operating Temperatures ........................................... 14Ozone Depleting Substance (ODS) ...................................... 14Emission Control Information Label ...................................... 14Calif. Fuel Vapor Recovery ..................................................... 14Calif. Motor Vehicle Emission Control Label .......................... 14Radio Frequency Interference (RFI) ...................................... 15Fuel System ........................................................................... 16Brake System ......................................................................... 17

CANADIAN VEHICLES

Vehicle Identification .............................................................. 18Daytime Running Lamp (DRL) .............................................. 18Canadian Radio Frequency Interference (RFI) ..................... 18

TABLE OF CONTENTS

3

STATEMENTS OF CONFORMITY

The Statements of Conformity section, which begin on page 8 of this manual, lists the Federal Motor Vehicle Safety Standardsin effect on the date of manufacture of this incomplete vehicle that are applicable to the type(s) of completed vehicles into whichthis incomplete vehicle may be manufactured. This date is shown on the label affixed to the cover of this manual. Thesestatements, in most cases, apply to specific types of incomplete or completed vehicles and identify GVWR and UVW weightranges.

The incomplete vehicle type is identified by the 5th, 6th, and 7th digits of the Vehicle Identification Number (VIN). The completedvehicle types to which this incomplete vehicle may appropriately be completed is printed on the label, under the heading “MayBe Completed As,” that is affixed to the cover of this document.

Each statement of conformity is identified by a safety standard number located at the left margin. Because there may be multiplestatements of conformity for each safety standard, use care to select the appropriate statement. Unique CMVSS requirementswill be identified at the conclusion of the representations for a particular safety standard.

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

Type I • A statement that the vehicle, when completed, will conform to the standard if no alterations are made in identifiedcomponents of the incomplete vehicle.

Type II • A statement of specific conditions of final manufacture under which the incomplete vehicle manufacturer specifiesthat the completed vehicle will conform to the standard.

Type III • A statement of conformity with the standard is not substantially affected by the design of the incomplete vehicle, andthat the incomplete vehicle manufacturer makes no representation as to conformity with the standard.

UNITED STATES VEHICLES(Vehicles to be completed for sale or use in the United States)

GENERAL INFORMATION

Information in this section is provided pursuant to Part 568 of Title 49, Code of Federal Regulations. “Vehicles Manufactured inTwo or More Stages.” Part 568 specifies that final stage manufacturers must complete vehicles in compliance with all applicableFederal Motor Vehicle Safety Standards and affix a label to each Incomplete Vehicle that it completes in accordance with 567.5of title 49.

DIRECTIONS

4

IMPORTANT:

TO RELY ON THE COMPLIANCE REPRESENTATIONS IN THIS MANUAL, THEVEHICLE MUST BE COMPLETED AS ONE OF THE COMPLETED VEHICLE TYPESDESIGNATED ON THE LABEL AFFIXED TO THE COVER OF THIS MANUAL, ANDMUST NOT EXCEED THE SPECIFIED GVWR, GAWRS OR THE UNLOADEDVEHICLE WEIGHT LIMITS WHEN SPECIFIED IN THIS MANUAL.

FORD LIGHT TRUCK ASSISTANCE

Throughout this manual you will find references to information found in the FordTruck Body Builders’ Layout Book. To obtain a free copy of this publication on CD-ROM or to receive an order form for additional CD-ROM’s or books please visit ourwebsite at www.fleet.ford.com/truckbbas/. Under Publications select Body BuildersOrder Forms. All dealer requests can be handled online. All other U.S. orders shouldbe faxed to (734) 713-2971. Canadian orders should be faxed to (905) 670-0844.

The Ford Light Truck Body Builder Advisory Service assistance may be consultedregarding information contained in this manual. For assistance:

• Call (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 and telephone number with all inquiries. If requestingwritten materials, include your mailing address.

IMPORTANT:

UNITED STATES AND CANADIAN VEHICLES

COMPLIANCE REPRESENTATIONS IN THIS MANUAL ARE ACCURATE FORINCOMPLETE VEHICLES AS MANUFACTURED BY OR FOR FORD MOTORCOMPANY. FURTHER MANUFACTURE, MODIFICATIONS, OR ALTERATIONS TOAN INCOMPLETE VEHICLE BY SOMEONE OTHER THAN FORD MOTORCOMPANY, OR DAMAGE IN TRANSIT, MAY AFFECT COMPLIANCE STATEMENTSTHAT ARE REPRESENTED IN THIS MANUAL.

THE INCOMPLETE VEHICLE WITH WHICH THIS MANUAL IS INCLUDED ISSUITABLE FOR COMPLETION ONLY AS A MULTI-PURPOSE PASSENGERVEHICLE OR A BUS OTHER THAN A SCHOOL BUS HAVING THE GVWRSPECIFIED ON THE FRONT COVER OF THIS MANUAL. IT IS NOT SUITABLE FORCOMPLETION AS EITHER AN AMBULANCE OR A SCHOOL BUS.

5

INCOMPLETE VEHICLE MANUAL COVER

The cover of this manual identifies the incomplete vehicle forwhich compliance representations are contained in thismanual. Also, a label is affixed to the cover which includes theVehicle Identification Number (VIN) for the specific vehicle towhich this manual belongs. The label identifies the followinginformation which pertains only to the vehicle with thecorresponding VIN.

• The GVWR.

• The front and rear GAWRs.

• Tire and wheel size.

• Cold tire inflation pressure (kPa/PSI).

• Completed vehicle type(s) into which the incompletevehicle may be manufactured.

INCOMPLETE VEHICLE LABEL

The incomplete vehicle label for the Basic (Stripped) Chassisis located inside the protective plastic bag for this manual. Adetailed explanation of all label information is available in theFord Source Book for the appropriate model year, at yourlocal Ford Dealer. Federal law requires that an IncompleteVehicle Label be affixed to the completed vehicle. Placementon the interior driver-door lock pillar near the driver’s seat isrecommended.

The 5th, 6th, and 7th digits of the Vehicle Identification Number(VIN) will identify the incomplete vehicle type. Additional VINinformation is available in the Ford Source Book for theappropriate model year.

California Air Resources Board (CARB), requires a VehicleEmission Control Label with a vehicle identification number(VIN) having a non-contact, bar-code, reading wand capability.The bar-code directly below the VIN on the incomplete vehiclelabel will comply with this regulation.

VEHICLE DESCRIPTION

6

Ambulance – is a vehicle for emergency medical care whichprovides: A driver’s compartment; a patient compartment toaccommodate an Emergency Medical Technician (EMT),Paramedic, and two litter patients (one patient on theprimary cot and secondary patient on folding litter locatedon the squad bench) so positioned that the primary patientcan be given intensive life-support during transit; equipmentand supplies for emergency care at the scene as well asduring transport; two-way radio communication; and, whennecessary, equipment for light rescue/extricationprocedures. The Ambulance shall be designed andconstructed to afford safety, comfort, and avoid aggravationof the patient’s injury or illness. (From Federal SpecificationKKK-A-1822-D). Ford Motor Company also includes withinits definition of ambulance any vehicle that is used fortransporting life-support equipment, for rescue operations,or for non-emergency patient transfer if the engine of thevehicle is equipped with a “throttle kicker” device, whichenables an operator to increase engine speed over normalidle speed when the vehicle is not moving.

Bus – a motor vehicle with motive power, except a trailer,designed for carrying more than 10 persons.

Bus (Canada) – a vehicle having a designated seatingcapacity of more than 10, but does not include a trailer or avehicle imported temporarily for special purposes.

Chassis Cab – an incomplete vehicle, with completedoccupant compartment, that requires only the addition ofcargo-carrying, work performing, or load-bearingcomponents to perform its intended function.

Critical Control Item – is a component or procedure whichmay affect compliance with a federal regulation or, whichcould directly affect the safe operation of the vehicle. Theidentifying symbol is an inverted delta ( ). (source: FordMotor Company)

Designated Seating Position – any plan view location capableof accommodating a person at least as large as a 5thpercentile adult female, if the overall seat configurationand design and vehicle design is such that the position islikely to be used as a seating position while the vehicle isin motion, except for auxiliary seating accommodationssuch as temporary or folding jump seats. Any bench orsplit-bench seat in passenger car, truck, or multipurposepassenger vehicle with a GVWR of 10,000 pounds or less,having greater than 50 inches of hip room (measured inaccordance with SAE Standard J1100(a)) shall have notless than three designated seating positions, unless theseat design or vehicle design is such that the center positioncannot be used for seating.

Designated Seating Position (Canada) – any plan viewposition capable of accommodating a person at least aslarge as a 5th percentile adult female, as defined in section100 of Schedule IV, where the overall seat configurationand design and the vehicle design are such that the positionis likely to be used as a seating position while the vehicleis in motion, but does not include any plan view position oftemporary or folding jump seats or other auxiliary seatingaccommodation.

Final Stage Manufacturer – a person or company whoperforms such manufacturing operations on an incompletevehicle that it becomes a completed vehicle.

Forward Control – a vehicle configuration in which more thanhalf of the engine length is rearward of the foremost pointof the windshield base and the steering wheel hub is in theforward quarter of the vehicle length.

Gross Axle Weight Rating (GAWR) – the value specified bythe vehicle manufacturer as the load-carrying capacity of asingle axle system, as measured at the tire-groundinterfaces.

Gross Combination Weight Rating (GCWR) – the valuespecified by the manufacturer as the loaded weight of acombination vehicle.

Gross Vehicle Weight Rating (GVWR) – the value specifiedby the manufacturer as the loaded weight of a singlevehicle.

H-Point – the mechanically hinged hip point of a manikin whichsimulated the actual pivot center of the human torso andthigh, described in SAE Recommended Practice J826,“Manikins For Use in Defining Vehicle SeatingAccommodation,” November 1962.

H-point (Canada) – the mechanically hinged hip point of amanikin that simulates the actual pivot centre of the humantorso and thigh, described in SAE Standard J826 APR80,Devices for Use in Defining and Measuring Vehicle SeatingAccomodation.

Incomplete Vehicle – an assemblage consisting, as aminimum, of frame and chassis structure, power train,steering system, suspension system, and braking system,to the extent that those systems are to be part of thecompleted vehicle, that requires further manufacturingoperations, other than the addition of readily attachablecomponents such as mirrors or tire and rim assemblies, orminor finishing operations, such as painting, to become acompleted vehicle.

Incomplete Vehicle (Canada) – (a) a vehicle other than avehicle imported temporarily for special purposes, that iscapable of being driven and that concists, at a minimum, ofa chassis structure, power train, steering system,suspension system and braking system in the state in whichthose systems are to be part of the completed vehicle, butrequires further manufacturing operations to become acompleted vehicle or (b) that is an incomplete trailer;(vehicule incompler).

Incomplete Vehicle Manufacturer – a person or companywho manufactures an incomplete vehicle by assemblingcomponents none of which, taken separately constitute anincomplete vehicle.

DEFINITIONSThe following definitions are from Title 49, Code of Federal Regulations, Part 571.3except where noted. Canadian definitions are from Canada Motor Vehicle SafetyRegulations, Section 2(1), and are in italics. Ford Motor Company definitions are forthe purpose of this manual only. Some terms are followed by an abbreviation that isused throughout this manual.

7

Intermediate Manufacturer – a person or company, otherthan the incomplete vehicle manufacturer or the final stagemanufacturer, who performs manufacturing operations onan incomplete vehicle.

Multipurpose Passenger Vehicle (MPV) – a motor vehiclewith motive power, except a trailer, designed to carry 10persons or less which is constructed either on a truckchassis or with special features for occasional off-roadoperation.

Multipurpose Passenger Vehicle (MPV) (Canada) – a vehiclehaving a designated seating capacity of 10 or less that isconstructed either on a truck-chassis or with special featuresfor occasional off-road operation, but does not include anair cushion vehicle, an all-terrain vehicle, a low-speedvechicle, a golf-cart, a passenger car, a truck or a vehicleimported temporarily for special purposes.

Prescribed Class (Canada) – a class of vehicles listed inSchedule III.

Seating Reference Point – the manufacturer’s designreference point which:

(a) Establishes the rearmost normal design driving or ridingposition of each designated seating position in a vehicle;

(b) Has coordinates established relative to the designedvehicle structure;

(c) Simulates the position of the pivot center of the humantorso and thigh; and

(d) Is the reference point employed to position the twodimensional templates described in SAE RecommendedPractice J826. “Manikins for Use in Defining VehicleSeating Accommodation,” November, 1962.

Seating Reference Point (Canada) – the unique Design H-point, as defined in section 2.2.11.1 of SAE RecommendedPractice J1100 (June 1993), that:

(a) Establishes the rearmost normal design driving or ridingposition of each designated seating position, takinginto account all modes of adjustment-horizontal, verticaland tilt-in a vehicle;

(b) Has X, Y and Z coordinates, as defined in section 2.2.3of SAE Recommended Practice J1100 (June 1993),established relative to the designed vehicle structure;

(c) Simulates the position of the pivot center of the humantorso and thigh; and

(d) Is the reference point employed to position the H-pointtemplate with the 95th percentile leg, as described insection 3.1 of SAE Standard J826 (June 1992), or, ifthat drafting template cannot be positioned, thereference point when the seat is in its rearmostadjustment position.

Second Unit Body (SUB) – consists of the body structureand/or all the cargo carrying, work performing, and/or loadbearing components and/or equipment installed by asubsequent stage manufacturer on an incomplete vehicle,such that the incomplete vehicle becomes a completedvehicle. (source: Ford Motor Company).

DEFINITIONS

School Bus – a bus that is sold or introduced in interstatecommerce for purposes that include carrying students toand from school or related events, but does not include abus designed and sold for operation as a common carrierin urban transportation.

School Bus (Canada) – a bus designed or equipped primarilyto carry students to and from school.

Subsequent Stage Manufacturer – is a term which meanseither intermediate or final stage manufacturers or both.(source: Ford Motor Company).

Trimmed Seat – a complete functional seat assembly includingthe seat pedestal, seat track, seat base frame, seat back,recliner mechanism, seat padding, all attaching hardware,and the final trim material (i.e., cloth, leather, or vinyl).(source: Ford Motor Company).

Truck – a motor vehicle with motive power, except a trailer,designed primarily for the transportation of property orspecial purpose equipment.

Truck (Canada)– a vehicle designed primarily for thetransportation of property or special-purpose equipmentbut does not include a competition vehicle, a crawler-mounted vehicle, a trailer, a work vehicle, a vehicleimported temporarily for special purposes or a vehicledesigned for operation exclusively off-road; (camion).

Truck-Tractor – a truck designed primarily for drawing othermotor vehicles and not so constructed as to carry a loadother than a part of the weight of the vehicle and the load sodrawn.

Truck Tractor (Canada) – a truck designed primarily fordrawing other vehicles and not constructed for carryingany load other than part of the weight of the vehicle andload drawn, and includes a vehicle designed to accept afifth-wheel coupling but does not include a crane-equippedbreakdown vehicle.

Unloaded Vehicle Weight (UVW) – the weight of a vehiclewith maximum capacity of all fluids necessary for operationof the vehicle, but without cargo, occupants, or accessoriesthat are ordinarily removed from the vehicle when it is not inuse.

Unloaded Vehicle Weight (Canada) – the weight of a vehicleequipped with containers for the fluids necessary for theoperation of the vehicle filled to their maximum capacity butwithout cargo or occupants.

Walk-In Van – is a step entry city delivery van type vehicle thatpermits a person to enter the vehicle without stooping. Thisdefinition by Ford Motor Company is based on informtationappearing in 41 FR 54945, published December 16, 1976,and in 42 FR 34288, published July 5, 1977.

Walk-In Van (Canada) – a van type of truck in which a personhaving a height of 1 700 mm can enter the occupantcompartment in an upright position by a front door.

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101 Conformity with Standard 101, Controls and Displays isnot substantially affected by the design of this incompletevehicle; accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard.

102 This vehicle, when completed, will conform to Standard102, Transmission Shift Lever Sequence, Starter Interlock,and Transmission Braking Effect, if:

No alterations or adjustments are made to thetransmission, shift cable, transmission outer shift lever,shift cable bracket, the starter interlock system andwiring circuit from the interlock switch to the powersource.

The Basic (Stripped) Chassis is equipped with atemporary transmission gear selector indicator(PRND21) which must be replaced with thetransmission gear selector indicator (PRND21) that isshipped with the vehicle in the dunnage box andinstalled and adjusted following the instructions andspecifications shown in the figure below.

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

103 Conformity with Standard 103, Windshield Defrosting andDefogging Systems, is not substantially affected by thedesign of this incomplete vehicle; accordingly, Ford MotorCompany makes no representation as to conformity withthis Standard.

104 Conformity with Standard 104. Windshield Wiping andWashing Systems, is not substantially affected by thedesign of this incomplete vehicle; accordingly, Ford MotorCompany makes no representation as to conformity withthis Standard.

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

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

3. Rotate the column shift lever clockwise until it bottoms out in firstgear.

4. Rotate the column shift lever counter-clockwise 2 detents forOverdrive “Oval D” position for 4R100 Transmissions.

5. Install a 3 pound weight, as defined in this illustration, on the end ofthe column shift lever.

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

7. Remove the 3 pound weight. The pointer must be within thetolerances as defined in this illustration.

8. After the steering column shrouds are installed, the transmissiongear selector indicator (PRND21) system must be checked forproper operation.

FIGURE A - INSTALLATION OF GEAR SELECTOR INDICATOR (PRND21)

•

•

000000

18

H

0 0 0 0

5060

70

80

90

100

10

20

30

40

0MPH

UNLEADED FUEL ONLY

BRAKE

SERVICEENGINE SOON

F

H

C

E

P R N 1

INSTRUMENTCLUSTER

CABLE

STEERINGCOLUMN

CABLE THUMB WHEEL

COLUMN SHIFTLEVER

FRONT OFVEHICLE

CABLE RETENTIONBRACKET

SHIFT LEVERRETAINER PIN

N800705 SCREWTORQUE 20−29 IN.−LB.

[ ] ALL DIMENSIONS ARE INCHES

3.0 − 3.5 LB. WEIGHTHAND TOOL[2.375] 0.25 DIA.

(PRND21)

HOLE: [1.125] DIA.X [2.188] 0.25 DEEP

(PRND21) ADJUSTMENT TOLERANCE

4R100 & 4R70W TRANSMISSION

+

−

+

−

RIGHT LIMITLEFT LIMIT TARGET

D

+−

+−

4R100 TRANSMISSIONS

(PRND21) ADJUSTMENT TOLERANCE

STATEMENTS OF CONFORMITY

The following Statements of Conformity apply to vehicles that are produced for sale or importation into the United States orCanada. The term “Incomplete Vehicle Types” in these statements refers to the type of the vehicle illustrated on this manual’scover and as defined in the Vehicle Description section on page 5.

The number preceding each Statement of Conformity refers to the number designation of a Federal Motor Vehicle SafetyStandard.

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

SCREW IS PIA TO CABLETORQUE IS 18-23 IN.-LB.

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105 This vehicle when completed, will conform to Standard105, Hydraulic Brake Systems, if:

No alterations, modifications, or replacements are madeto the following:

Service or parking brake system

Antilock brake system

Wheels and tires

Brake system indicator lamp and wiring

Brake system reservoir labeling

Suspension ride height or spring rate

Hydro-boost or Hydro-max system

Power steering pump and lines

Engine Belt Drive System

The Second Unit Body (SUB) weight is at least 889kilograms (1960 lbs).

Vertical distance from the center of gravity of thecompleted vehicle to the ground is 1219 mm (48 inches)or less.

The maximum GAWR and GVWR, as identified on thecover of this document, are not exceeded with thevehicle weight at Unloaded Vehicle Weight + PassengerLoad.

Refer to the Brake System section for further information.

The service or parking brake pedal assembly operationis not restriced by any alteration or added components.

NOTE: Under no circumstances can individual GAWR’sbe exceeded or can the GVWR be exceeded.

2003 F-Super Duty Class A Motorhome Chassis ratedat 22,000 lbs. (Available with 208” or 228” WB only):

GVWR = 22,000 lbs.GAWR = 7,500 lbs. - FrontGAWR = 14,500 lbs. - Rear



2003 F-Super Duty Class A Motorhome Chassis ratedat 18,000 lbs.:




•

••

•

•

••

•••

•

•

EQUATION (1)

CGv =

EQUATION (2)

CGh =

CGvbWb + CGvc Wc + Wl 12,500 GVWR

GVWR

500 x CGhpWB

Wrb+ Wrc + + Wrl x WB)) )

)

••

•

CENTER OF GRAVITY

If the center of gravity of the SUB is not forward of thecenterline of the rear axle and the SUB is not above theminimum weight, then the center of gravity location mustbe verified.

Center of gravity and weight of the second unit body (SUB)and/or added equipment (Wb) must be such that thecompleted vehicle center of gravity locations (asapproximated in equations 1 and 2) fall within theappropriate region given below.

)

)

Using the CGh of the vehicle (from equation 2), equations3 and 4 below will determine the allowable range of CGvif the actual CGv (from equation 1) is within the calculatedrange, then the center of gravity location is acceptable.

3) Upper Limit:CGv = 1.27 x CGh - 97.03 (For 178” WB)

CGv = 1.27 x CGh - 103.57 (For 190” WB)

CGv = 1.27 x CGh - 113.34 (For 208” WB)

CGv = 1.27 x CGh - 124.24 (For 228” WB)

4) Lower Limit:CGv = 1.27 x CGh - 108.31 (For 178” WB)

CGv = 1.27 x CGh - 115.61 (For 190” WB)

CGv = 1.27 x CGh - 126.60 (For 208” WB)

CGv = 1.27 x CGh - 138.77 (For 228” WB)

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CGv = Vertical distance from the ground to the completedcenter of gravity [inches].

CGh = Horizontal distance from of the front wheels tocompleted vehicle center of gravity [inches].

CGvb = Vertical distance from the ground to the center ofgravity of the SUB and/or permanently attachedadded equipment [inches]. (See the CalculationSuggestions Section on page 11).

CGvc = Vertical distance from the ground to the center ofgravity of the chassis [24.85 inches].

CGhp = Horizontal distance from the of the front wheelsto the 500 pounds passenger weight.

Wb = Weight of the SUB and/or permanently attachedadded equipment [pounds].

Wrb = Weight on the rear wheels of the SUB and/orpermanently attached added equipment[pounds].

Wrc = Weight at the rear wheels of the vehicle chassis(fuel tanks full) [pounds]. Including option weight.

Wc = Weight of the vehicle chassis (fuel tanks full)[pounds]. Including option weight.

WB = Vehicle wheelbase [178, 190, 208 or 228 inches].

Wt = Total unladen weight = (Wb + Wc + 500#) [pounds].

GVWR = Gross Vehicle Weight Rating of the vehicle[pounds].

WI

= Remaining cargo capacity [pounds].

Where: Wl = GVWR - (Wb + Wc + 500#)

Wrl = Weight of the remaining cargo capacity on therear wheels [pounds].

CGhI = Horizontal distance from the of the front wheelsto the cargo center of gravity [inches]. It may beestimated as the distance from the of the frontwheel to the horizontal midpoint of the cargo area.

SUB = A Second Unit Body consists of all the cargocarrying, work performing, and/or load bearingcomponents and/or equipment installed by asubsequent stage manufacturer on an incompletevehicle, such that the incomplete vehicle becomesa completed vehicle.

FMVSS 105 DEFINITIONS

CL

CL

CL

CL

11

105 Calculation Suggestions:

In the case where the rear weight of the SUB (and/oradded equipment) must be reduced or the CGv is foundto be below the allowed minimum CGv, then it may bepossible to bring the vehicle into compliance by movingthe CGh forward. Forward movement of the CGh can beaccomplished by:

Redistributing the weight of the SUB and/or addedequipment.

Adding permanently attached ballast forward of theCGh. In order to reduce the rear weight, the ballastmust be forward of the front axle. (Caution must betaken not to exceed the GVWR or front GAWR of thevehicle.)

The following general equations can be used to find thecenter of gravity of the SUB and/or added equipmentwhen there are several elements making up the CG.

••

CGvb =CGvb1 Wb1 + CGvb2 Wb2 +...+CGvbn Wbn

Wb1

+ Wb2

+...+Wbn

)

)

)

)

)

)

and the horizontal CG locations of the combined SUBand/or added equipment is:

CGhb =Wrb1 Wrb2 +...+ Wrbn WB

Wb1

+ Wb2

+...+Wbn

))

The front/rear weight breakdown can be found with theuse of the following equation.

Wrb =CGhb Wb1 + Wb2 +...+ Wbn

WB)

)

Conversely, the front weight component of the SUB and/or added equipment is:

Wfb

= Wb1

+ Wb2

+...+ Wbn

- Wrb)

)

NOTICE – 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 are importantto the handling of the completed vehicle. Subsequentstage manufacturers should note that matching a body toa chassis in a manner appropriate for the intended use ofthe vehicle is the responsibility of the final stagemanufacturer. Following the representations of thismanual with respect to center of gravity locations andbody weights for compliance with Federal Motor VehicleSafety standards is only part of the task of producing acompleted vehicle that handles comfortably in service.

106 This vehicle when completed, will conform to Standard106, Brake Hoses, if the brake hose assembliessupplied by Ford Motor Company are not removed,altered or replaced and if no brake hose assembliesare added.

108 Conformity with Standard 108, Lamps, Reflective Devices,and Associated Equipment, is not substantially affectedby the design of this incomplete vehicle; accordingly, FordMotor Company makes no representation as to conformitywith this standard. However, Ford Motor Company doesrepresent that the items of lighting equipment provided inthe dunnage box attached to the chassis are designed toconform to the requirements of Standard 108.

108 Canadian Requirements:

The preceding statements for FMVSS 108 are appropriatecompliance representations for CMVSS 108, Lighting,and CMVSS 108.1, Headlamps, if this vehicle ismanufactured for sale or use in Canada, provided:

No component of the Daytime Running Lamp (DRL)system is removed, relocated, or modified.

111 Conformity with Standard 111, Rearview Mirrors, is notsubstantially affected by the design of this incompletevehicle; accordingly Ford Motor Company makes norepresentation as to conformity with this Standard.

113 Conformity with Standard 113, Hood Latch Systems, isnot substantially affected by the design of this incompletevehicle; accordingly Ford Motor Company makes norepresentaton as to conformity with this Standard.


The statements for Part 565.4 are appropriate compliancerepresentations for CMVSS 115, Vehicle IdentificationNumber, if this incomplete vehicle was manufactured forsale or use in Canada.

116 This vehicle, when completed, will conform to Standard116, Motor Vehicle Brake Fluids, so long as any brakefluid added or replaced conforms to the DOT 3specifications of the standard, and contaminants are notintroduced into the hydraulic brake system.

119 The statement below is applicable to all incompletevehicle types:

All tires supplied by Ford Motor Company are in fullconformity with Standard 119, New Pneumatic Tires forVehicles Other than Passenger Cars.

If additional tires are installed or the existing tires arereplaced by subsequent stage manufacturers, they mustconform to the requirements of Standard 119.

120 This vehicle, when completed, will conform to the tire andrim selection requirements of Standard 120, TireSelection and Rims for Motor Vehicles Other ThanPassenger Cars, if the tire or rim assemblies and theIncomplete Vehicle Label affixed to all vehicles, (exceptthe Basic (Stripped) Chassis), are not removed, alteredor replaced. For the Basic (Stripped) Chassis, the finalstage manufacturer must, in accordance with therequirements of Standard 120 and Part 567 of Title 49Code of Federal Regulations either affix a label indicatingtire size, rim size and cold inflation pressure informationand gross axle weight ratings that are printed on the labelaffixed to the cover of this manual, or affix the IncompleteVehicle Label included in the plastic bag along with thisIncomplete Vehicle Manual.

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124 This vehicle when completed, will conform to Standard124, Accelerator Control Systems, if:

No alterations are made to the accelerator control rod,bellcranks, cables, springs, guides, accelerator pedal,mounting hardware or other components of theaccelerator control system as installed by Ford MotorCompany.

No equipment is added, or existing equipment ismodified, which would restrict operation of theaccelerator control system.

205 Conformity with Standard 205, Glazing Materials, is notsubstantially affected by the design of this incompletevehicle; accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard.

206 Conformity with Standard 206, Door Locks and DoorRetention Components, is not substantially affected bythe design of this incomplete vehicle; accordingly, FordMotor Company makes no representation as to conformitywith this Standard.

207 Conformity with Standard 207, Seating Systems, is notsubstantially affected by the design of this incompletevehicle; accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard.

208 Conformity with Standard 208, Occupant Crash Protection,is not substantially affected by the design of thisincomplete vehicle; accordingly, Ford Motor Companymakes no representation as to conformity of this vehicle.Any seat belt assemblies added to a vehicle must conformto the applicable requirements of this Standard.

209 Conformity with Standard 209, Seat Belt Assemblies, isnot substantially affected by the design of this incompletevehicle; accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard.

210 Conformity with Standard 210, Seat Belt AssemblyAnchorages, is not substantially affected by the design ofthis incomplete vehicle; accordingly, Ford Motor Companymakes no representation as to conformity with thisStandard.

213 Conformity with Standard 213, Child restraint systems, isnot substantially affected by the design of the incompletevehicle; accordingly Ford Motor Company makes norepresentation as to conformity with this Standard. Anychild restraint system that is added or incorporated intothe design of a designated seating position must conformto the requirements of this standard.

217 Conformity with Standard 217, Bus Window Retentionand Release, is not substantially affected by the designof this incomplete vehicle; accordingly, Ford MotorCompany makes no representation as to conformity withthis Standard.

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The preceding statements for FMVSS 217 are appropriatecompliance representations for CMVSS 217, BusEmergency Exit and Window Retention and Release,when a vehicle is completed as a Bus (not School Bus)and if this incomplete vehicle was manufactured for saleor use in Canada.

225 The statements below are applicable to all incompletevehicle types:

Conformity with Standard 225, Child Restraint AnchorageSystems, is not substantially affected by the design of thisincomplete vehicle; accordingly, Ford Motor Companymakes no representation as to conformity with thisStandard.

Any tether anchorage that is added to any vehicle mustcomply with the requirements of FMVSS 225.

301.1 Canadian Requirements:

Standard 301.1, LPG Fuel System Integrity, Ford MotorCompany makes no representation as to conformity withthis Standard.

301.2 Canadian Requirements:

Standard 301.2, CNG Fuel System Integrity, Ford MotorCompany makes no representation a to conformity withthis Standard.

302 Conformity with Standard 302, Flammability of InteriorMaterials, is not substantially affected by the design ofthis incomplete vehicle; accordingly, Ford Motor Companymakes no representation as to conformity with thisStandard.

This vehicle, when completed, will conform to Part 565.4Vehicle Identification Number, if the vehicle identificationnumber printed on the label affixed to the cover of thismanual is mounted and displayed in accordance withthe requirements of this standard.


The Basic (Stripped) Chassis as built by Ford is tooincomplete for Ford to be able to determine the extent towhich it would meet the Exterior Sound Levelrequirements of Section 2.(a) or (b) of Standard 1106,Noise Emissions, and therefore Ford makes norepresentation as to conformity to this requirement.

The Basic (Stripped) Chassis as built by Ford is notequipped with a cab or body structure and therefore Fordmakes no representation as to conformity to the InteriorSound Level requirement of Section 5, of Standard 1106.

Part565.4

13

Emission Control Hardware

Any body builder, installer, or subsequent stage manufacturermust also assure that all emission control hardware furnishedwith incomplete vehicles is on the vehicle and is operationaland that applicable instructions for incorporating suchhardware into the completed vehicle’s electrical or mechani-cal systems are strictly followed.

High Altitude Requirements

United States Environmental Protection Agency regulationsfor the 2003 model year do not contain unique emissioncertification requirements for light duty trucks that will be soldor delivered to customers for principal use above 1,219 m[4,000 ft.].

To avoid any question of certificaton coverage, approval ofany modification that may render inoperative any of theemission control components must be obtained from theUnited States Environmental Protection Agency by themanufacturer making such modification prior to distribution,sale, offering for sale introduction, or delivery for introductionof the subject vehicle into U.S. commerce. Additionally, themanufacturer making such modification must obtain approvalfrom the California Air Resources Board if the new vehicle willbe delivered for sale or use in the State of California.

IMPORTANT:It is the responsibility of the body builder, installer, orsubsequent stage manufacturer to ensure that themaximum completed vehicle curb weight specified by Fordis not exceeded. If this restriction is exceeded, or if thevehicle is modified such that it will not comply withapplicable emission standards throughout its useful life,the body builder, installer, or subsequent stagemanufacturer will be considered a manufacturer forpurposes of complying with U.S. Federal, California, orCanadian exhaust and evaporative emissionrequirements, and Federal fuel economy standards,labeling, and certain other requirements.

IMPORTANT:For purposes of Government Regulation, a body builder,installer, or any subsequent manufacturer may beconsidered a manufacturer.

EMISSION CERTIFICATION INFORMATION However, the Basic (Stripped) Chassis as built by Ford is tooincomplete to constitute a regulated vehicle and Ford doesnot represent that it complies with those regulations. Withrespect to the Basic (Stripped) Chassis, it is the responsibilityof the subsequent stage manufacturer of that vehicle at thetime it first conforms to the regulatory definition of “vehicle” tocomply with the requirements imposed upon manufacturersby these regulations.

TAMPERING WITH NOISE CONTROLSFederal law prohibits the removal or rendering inoperative byany person, other than for purposes of maintenance, repair,or replacement, of any device or element of designincorporated into such vehicle for the purpose of noise controlprior to its sale or delivery to the ultimate purchaser or while itis in use. Federal Law also prohibits the use of such vehicleafter such device or element of design has been removed orrendered inoperative by any person.

Among those acts presumed to constitute tampering are theacts listed below:

Removal of fender apron absorbers, fender apronbarriers, underbody noise shields, or acousticalabsorptive material.

Removal of or rendering inoperative the engine speedgovernor so as to allow engine speed to exceedmanufacturer’s specifications.

Removal of air duct, air intake choke or silencer, aircleaner or air cleaner element.

Removal of, or rendering inoperative, exhaust systemcomponents including the catalyst inlet pipe, muffler,outlet pipe, resonator or diffuser.

Removal of the fan shroud. Removal of or renderinginoperative the fan clutch.

New vehicles manufactured for sale in Canada must complywith applicable provisions of Canada Motor Vehicle SafetyStandard 1106, Noise.

Additional noise emissions information is contained in theFord Truck Body Builders’ Layout Book.

WARRANTY AND MAINTENANCEA copy of the appropriate Ford Truck Owners Guide andWarranty Facts Booklet must be installed in every vehicle priorto sale to the ultimate purchaser in order to provide emissionsystems warranty information and maintenance schedules. Italso provides, where required by EPA noise control regulationsfor vehicles having GVWR over 4536 kg [10,000 lb], noiseemissions warranty information, instructions for maintenance,use, and repair of vehicle noise emission control systems, amaintenance record format, and list of prohibited tamperingacts.

EVAPORATIVE EMISSIONSAll 2003 Federal light and heavy duty trucks and all Californiavehicles with gasoline engines are required to comply withevaporative emissions requirements established by theEnvironmental Protection Agency or the California AirResources Board. Production fuel systems supplied onincomplete 2003 model year trucks manufactured by FordMotor Company comply with these requirements. If thesubsequent stage manufacturer adds to or modifies thefuel system in any manner, it becomes the responsibilityof the modifier to assure compliance with the applicableregulations.

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UNLEADED GASOLINE LABELRegulations no longer require the manufacturer to affixpermanent labels reading “Unleaded Gasoline Only” or“Unleaded Fuel Only” to vehicles destined for sale in the UnitedStates or Canada. Such labels may however be required forvehicles sold into other markets. It is the responsibility of thebody builder, installer, or any subsequent manufacturer toproperly label vehicles for the market in which they are sold.

EXTERIOR NOISENew vehicles which have a gross vehicle weight rating inexcess of 4536 kg [10,000 lb], include a partially or whollyenclosed operator’s compartment, and are manufactured foruse in the United States, must comply with U.S. EnvironmentalProtection Agency’s exterior noise emission regulations formedium and heavy trucks (40 CFR Part 205, Subpart B) whichestablish a noise emission limit of 80 dB (A).

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SERVICE ENGINE SOON WARNING LIGHTThe “Service Engine Soon” warning light is used to indicatemalfunctions of the Electronic Engine Control System andcertain emissions-related components.

The Basic (Stripped) Chassis vehicles, have the warning lightinstalled in the instrument cluster, which is shipped in thedunnage box. If an alternative instrument cluster is utilized,the final stage manufacturer must install an operational lightin the instrument cluster. This light must glow amber and displaythe message “Service Engine Soon”. It should be recognizedthat this light is a requirement of emission certification.

WARNING – VEHICLE OPERATING TEMPERATURES

Certain exhaust system components, including exhaust, heatshielding systems, have been installed on some vehicles inour assembly plants in an effort to provide protection againstengine compartment and exhaust system temperatures.Subsequent aftermarket installers/manufacturers areresponsible for providing thermal protection (e.g. underbodyheat shields) for any structure and/or equipment added to thevehicle and should not remove any components or exhaustheat shielding installed on the vehicle by Ford.

All exposed interior sheet metal of closed structures (e.g. floorpan of cab and/or secondary structure, tool boxes, etc.) shouldbe covered with an insulating material capable of protectingvehicle occupants and contents from temperatures potentiallyup to 700°F.

OZONE DEPLETING SUBSTANCE (ODS)

The Clean Air Act of 1990, Section 611 requires any product(i.e., completed vehicle) containing or manufactured with anyClass I Ozone Depleting Substance on, or after May 15,1993must be identified with a “clearly and conspicuously attachedlabel.”

Ford Motor Company has eliminated Class I ODS from itsmanufacturing processes. All 2003 Ford Truck incompletevehicles will not have Class I ODS content.

Manufacturers, including subsequent stage manufacturers,are required to label their products if the product, includingany component (whether manufactured by that manufactureror not), contains a Class I ODS or if the manufacturer used aClass I ODS in the manufacturing of the product. In the casewhere Ford provides a label saying the incomplete vehiclecontains a Class I ODS that information must be placed on theproduct warning label. (See EPA regulation on wording,placement, size, and combining labels.) In Canada consultthe appropriate Provincial or Territorial Ministry of Environment.

EMISSION CONTROL INFORMATION LABEL

To meet United States Environmental Protection Agencyregulations, the Important Vehicle Information (tune-up andfuel tank capacity) labels must be affixed in a location that isreadily visible after installation and in such a manner that itcannot be removed without destroying or defacing the label.The label shall not be affixed to any equipment that is easilydetached from the vehicle.

When emission control labels are supplied but not attachedto the vehicle (i.e., tune-up label or fuel tank label), they mustbe permanently mounted in a readily visible location to meetthe preceding requirements. In addition, whether the label isalready affixed or to be affixed, no components shall beinstalled which visibly obscure the label in any way that failsto satisfy the visibility requirements described in the CaliforniaEmission Control Label Specifications. For Canadianrequirements consult Section 1100 8 (1) (d) (i), (ii), & (iii).

CALIFORNIA FUEL VAPOR RECOVERY

California regulations require that the vehicle fuel systems bedesigned to accommodate a vapor recovery fueling nozzleincluding unobstructed access to the fill pipe. Fuel filler pipesinstalled per the Figure B on page 15 will comply with the“Specifications For Fill Pipes and Openings of Motor VehicleFuel Tanks” referenced in Title 13 California AdministrativeCode provided no part of the aftermarket body, as installed,intrudes within a 254mm [10 in] radius cylinder which has itsaxis parallel to the ground at point “Z” and extends outwardfrom the Ford supplied fuel pipe housing component. The fuelpipe housing component is shown on the referenced figuresand is attached to the aftermarket body via 4.76 mm [.188 in.]diameter rivets. Fuel filler pipes installed using the alternativebracket shown in Figure B, will comply with the aboveCalifornia vapor recovery regulations provided the aftermarketbody does not interfere with the access zone as defined bythe California Air Resources Board, and the areas adjacent tothis opening cannot foreseeably damage the nozzle bellowsor face plate of nozzles during insertion, latching, disposingor removal.

CALIFORNIA MOTOR VEHICLE EMISSION CONTROLLABEL

To meet California emission certification regulations, theEmission Control Information (tune-up) label must be welded,riveted, or otherwise permanently attached to an area withinthe engine compartment or to the engine in such a way that itwill be readily visible to the average person after installationof the engine in a vehicle. In selecting an acceptable location,the manufacturer shall consider the possibility of accidentaldamage (e.g., possibility of tools or sharp instruments comingin contact with the label). The label shall be affixed in such amanner that it cannot be removed without being destroyed ordefaced, and shall not be affixed to any part which is likely tobe replaced during the vehicle’s useful life. As used in thesespecifications, readily visible to the average person shall meanthat the label shall be readable from a distance of 46 cm [18in] without any obstructions from vehicle or engine parts(including all manufacturer available optional equipment),except for flexible parts, (e.g., vacuum hoses, ignition wires).Alternately, information required by these specifications to beprinted on the label shall be no smaller than 8 point type sizeprovided that no vehicle or engine parts (including allmanufacturer available optional equipment), except for flexibleparts that can be moved out of the way without disconnection,obstruct the label.

Completed vehicles for retail sale in California require amachine-readable vehicle identification number (VIN) bar-code label made of paper, plastic, metal, or other permanentmaterial.

Conformity with CARB Motor Vehicle Emission Control Labelspecifications for VIN label is not substantially affected by thedesign of this incomplete vehicle. Accordingly, Ford MotorCompany makes no representation as to conformity with thisrequirement. To assist a subsequent stage manufacturer withconforming to this specification Ford is providing a label whichwill accompany this manual inside the protective plastic bag.

For the VEC† and VIN labels, sufficient clearance shall beprovided to use a non-contact bar-code Reading Wand. Forthe tune-up label and vacuum hose routing diagram label,the label and any adhesives used shall be designed towithstand for the vehicle’s total expected life, typical vehicleenvironment conditions in the area where the label is attached.Typical vehicle environmental conditions shall include, butare not limited to, exposure to engine lubricants and coolants(e.g., gasoline, motor oil, brake fluids, water, ethyleneglycol), under hood temperatures, steam cleaning, and paintsor paint solvents.

† Vehicle Emission Control

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FIGURE B – F-SERIES DUTY CLASS A MOTORHOME CHASSIS (F53) FUEL FILLER PIPE INSTALLATION

RADIO FREQUENCY INTERFERENCE (RFI)

The ignition system on your F-Super Duty Class A MotorhomeChassis has been designed to be capable of compliance withRFI requirements established by the Canadian government.However, because Ford has no control over how anincomplete vehicle is completed by subsequent stagemanufacturers, Ford does not represent that the completedvehicle incorporating the Ford-built components will complywith those requirements. Any ignition system component(i.e.: spark plugs, ignition wiring, coil suppressor assembly,etc.) that is replaced should be replaced by the same FordMotor company part number or equivalent to maintain RFIsuppression.

While there are currently no RFI regulations in the UnitedStates specifically applicable to automotive ignition systems,all Ford Light Trucks are built with ignition system componentsthe same or equivalent to those supplied on Canadianvehicles.

Ford Motor Company recommends that all ignition systemservice be performed at a Ford authorized service facility tohelp hold RFI emissions levels to a minimum.

Additional RFI information is contained on page 18 of thismanual.

Devices that emit radio frequency (RF) energy such as AM/FM radios, mobile telecommunications systems (two-wayradios, telephones), and radio controlled security systemsare subject to the rules and regulations of the FederalCommunications Communication (FCC), including 47 CFRParts 2 and 15. Any such system installed in a vehicle shouldcomply with those rules and should be installed only by aqualified technician. In addition, to ensure continuedcompliance with the FCC’s regulations, RF devices must notbe modified or changed in a manner not expressly approvedby Ford Motor Company Mobile Communication Systems. RFdevices particularly, if not properly installed, may adverselyaffect the operation of the vehicle. For example, such systemswhen operated may cause the engine to stumble or stall. Inaddition, such systems themselves may be damaged, or theiroperation affected by the operation of the vehicle. (CitizensBand [CB] transceivers, garage door openers, and othertransmitters whose power output is 5 watts or less, ordinarilywill NOT affect vehicle operation.)

Because Ford has no control over the operation ormanufacture of such systems or their installation, Ford cannotassume responsibility for any adverse effects or damage ifthis equipment is used.

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16

FIGURE C - STEEL FUEL LINE PUSH-CONNECT

RETAINER − FUEL TUBEPUSH CONNECTOR

SUPPLY − E9UA−9J278−AARETURN − E9UA−9J278−BA

F65A−9J274−CACOMMON SUPPLY/RETURN

BEFORE OPENING THE FUEL SYSTEM ON VEHICLESWITH EFI ENGINES, RELIEVE FUEL PRESSURE BYFOLLOWING THE INSTRUCTIONS IN THE FORD SHOPMANUAL FOR THE APPROPRIATE MODEL AND MODEL YEAR.

WARNING

REMOVAL TOOL

ECONOLINE:

SUPER DUTY F−SERIES

REMOVAL TOOL

WARNINGBEFORE OPENING THE FUEL SYSTEM ON VEHICLES WITHEFI ENGINES, RELIEVE FUEL PRESSURE BY FOLLOWINGTHE INSTRUCTIONS IN THE FORD TRUCK SHOP MANUALFOR THE APPROPRIATE MODEL AND MODEL YEAR.

��

FUEL SYSTEM DIAGRAM

FUEL SYSTEM

The push connectors on steel fuel lines must be connected bysnapping them into position and installing the appropriateRetainer as shown in Figure C.

When welding near fuel system components, all metalliccomponents must be adequately shielded and protected fromheat or weld splatter. All non-metallic components must beremoved.

For this Basic (Stripped) Chassis equipped with a temporaryfuel tank, the fuel tank sending unit must be removed from thetemporary tank and installed in the permanent tank. Prior tothe installation of the sending unit, the temporary shippingcover must be removed from the fuel tank sender opening.The temporary fuel lines to the temporary tank are removedby snapping off the retention tabs on the push connect clipsand sliding out the clips using the removal tool, available fromFord Customer Service Division, as shown in Figure C. Thetemporary shipping lines are not to be reused. The mainfuel lines msut be connected to the locations from which thetemporary lines were removed. The sending unit is theninstalled in the permanent tank by using the six new nuts andthe new O-ring seal that is shipped with the vehicle in aseparate package. The six nuts must be torqued to 9 + 1.4 NmNewton-meters (80 + 12 in.-lbs.). Special connecting fuel lineswith female metal push connectors are used to connect thesteel fuel lines to the fuel sender on the tank. The connectorsmust be snapped securely into place and the appropriateRetainer-Fuel Tube Push Connector is installed as shown inFigure C.

The Basic (Stripped) Chassis, with an Electronic Fuel Injection(EFI) type engine is equipped with a Fuel Shut Off Switch. Theswitch is located on the steering column support structure,and must not be relocated, altered or modified in any way.

FUEL FILLER PIPE INSTALLA TION

Ford Motor Company tests the provided fuel filler kit in arepresentative Motorhome to verify that it is capable ofproviding adequate fuel filling function. However, Ford has nocontrol over how the filler pipe and vent line is modified orinstalled by the Vehicle Modifier. Consequently, the VehicleModifier must ensure that the fuel filler pipe and any extensionsadded to the fill or vent lines provide a continuous down slopefrom the filler pipe inlet to the fuel tank inlet, and are adequatelysupported to prevent sagging that could cause spray, spitbackor premature shutoff during normal fueling operations. TheFinal Stage Manufacturer is responsible for verifyingacceptable fuel fill function on the completed vehicle.

Lengthening/relocating the fuel filler pipe can only be donewith the hose supplied in the dunnage box and steel tubeprovided by the body builder. No substitute hose material isallowed. Total length of the hose used in the system cannotexceed that of the original hose supplied in the dunnage box.Failure to comply may void the evaporative emissionscertification. See Ford Body Builders Layout Book for furtherinformation.

No additional hose can be added to the canister purge lines.Lengthening of the system can only be accomplished byreplacing one or more of the steel tubes with a longer tube.The number of joints and length of hose in the system cannotbe increased. If any of the hose is damaged, it must be replacedwith CADBAR II low permiability hose meeting FordEngineering Specification ESA-M2D50-B. Failure to complymay void the evaporative emissions certification.

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BRAKE SYSTEM

WARNING – Addition of T ag AxlesManufacturers that add a tag axle must ensure that the tagaxle:

Has an independent brake system appropriate to the tagaxle weight rating.

Brake system does not use the chassis brake system foractuation pressure (it can obtain a pressure signal fromthe chassis brake system).

Brake system works in conjunction with the chassis anti-lock brake system. Failure to do so could result in braking,handling and stability concerns.

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VEHICLE IDENTIFICATION

Refer to the Vehicle Description section of this manual on page5, for additional information.

DAYTIME RUNNING LAMP (DRL)

Compliance representations for CMVSS 108, Lighting andCMVSS 108.1, Headlamps, are on page 11. The followingitems are also required for CMVSS 108 and 108.1 compliance:

The DRL module circuits are not to be altered.

DRL module is not to be repositioned.

Basic (Stripped) Chassis is not to be equipped with morethan two headlamps when equipped with a DRL moduleas provided by Ford Motor Company.

CANADIAN RADIO FREQUENCY INTERFERENCE (RFI)INFORMATION

All vehicles powered by spark ignition engines (e.g.: gasoline,natural gas, or propane engines) and manufactured inCanada or for sale or use in Canada are subject to theCanadian “Regulations for the Control of Interference to RadioReception” per Interference-Causing Equipment Standard(ICES-002) and applicable test method according to “CAN/CSA-C108.4-M92”. Violation of these regulations ispunishable by fine or imprisonment. This Ford-built incompletevehicle (if other than a Basic (Stripped) Chassis) was designedand manufactured to be capable of meeting the regulatoryrequirements or such modifications thereof as may have beenauthorized by the Department of Communications. However,because Ford has no control over how this incomplete vehicleis completed by subsequent stage manufacturers, Ford doesnot represent that the completed vehicle incorporating theFord-built components will comply with applicablerequirements.

The following information is supplied to subsequent stagemanufacturers to help them avoid increasing the RFIemissions of this vehicle in the course of completing it.

For any completed vehicle, additional measures may beneeded to adequately suppress RFI emissions. Affectedcomponents could include spark plugs, ignition wires, ignitioncoil, ground straps, ignition component shields, accessorydrive belts, instrument voltage regulator suppressor assembly,and ignition coil suppressor assembly.

More specifically:

All components required to suppress RFI emissions, whichare removed during service, repair, or completion of thevehicle, must be reinstalled in the manner in which theywere installed by Ford.

Shields on distributor or ignition coil must remain installed.

Replacement spark plugs, ignition wires, ignition coil,distributor cap and distributor rotor must be equivalent intheir RFI suppression properties to original equipment.

The silicone coating on the distributor rotor tip must not beremoved.

Electrical grounds on all components must be retained.

Metallic components installed on the body or chassis mustbe grounded to the chassis.

Electrical circuits added to the vehicle must not be installednear the high voltage ignition components.

Only “static conductive” accessory drive belts should beused. Fan, water pump, power steering, and other beltsshould be of the OEM type or equivalent that will not buildup a static electrical charge.

Engine compartment wiring must not be rerouted in anymanner.

The Powertrain Control Module (PCM) must not berelocated from the position as installed by Ford MotorCompany.

CANADIAN VEHICLES(Vehicles to be completed for sale or use in Canada)

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SUPPLEMENTS

FORD MOTOR COMPANYTHE AMERICAN ROADDEARBORN, MI 48121

FORD MOTOR COMPANY OF CANADA LIMITEDTHE CANADIAN ROAD

OAKVILLE, ONTARIO L6J 5E4

2003 F-Super Duty Class A Motorhome Chassis Incomplete Vehicle ...

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