Ford - F 750 - Workshop Manual - 2002 - 2002

F-SERIES EXCURSION Expedition E-SERIES FOR 2002 North American Truck Special Vehicle Engineering 2002 Ford Truck “What’s New” Guide The purpose of this guide is to provide some advance insight into 2002 model year Ford Truck product features that may assist final stage manufacturers, and vehicle alteration companies, in preparing their production process. This guide is for reference only, reflecting information available as of September, 2001 and is subject to change without notice. It should be used in conjunction with other related Ford publications listed below. Methods to obtain these and other useful publications are described further in this manual. • Ford Truck Body Builders Layout Book • Incomplete Vehicle Manual This manual is the property of Ford Motor Company. Reproduction or use for any other purpose, without the permission of Ford Motor Company, is prohibited. TABLE OF CONTENTS Page Number 1 1 2-3 4-5 6 7 8 9 10 11 12-13 14-15 16 17-18 19 20 21 22 23 Subject Body Builder Quality Programs Job #1 Timing F-150 F-250/350/450/550 Super Duty PTO Circuit Installation, Electrical Wiring Trailer Tow Wiring Tap Schematic Schematic for Adding Lights or Electrical Devices F-650 Super Duty F-750 Super Duty F-53 Class A Motorhome Chassis E-Series Van / Cutaway / Stripped Chassis E-550 Super Duty Cutaway E-Series Customer Access Circuits, Electrical Wiring Excursion Expedition Tire Pressure Awareness Label Truck Body Builders Advisory Service Website Obtaining Publications • Ford Truck Body Builders Layout Book • Incomplete Vehicle Manual • Ford Recreation Vehicle and Trailer Towing Guide • Service Publications (i.e. Wiring Diagrams, Shop Manuals) • Body Builder Quality Bulletins Important Phone Numbers and Web Sites Body Builder Quality Programs The following organizations are established to provide technical assistance to vehicle modifiers of Ford Truck chassis. They are part of the Special Vehicle Engineering Department within the Ford North American Truck Consumer Business Group. • TRUCK BODY BUILDER ADVISORY SERVICE Provides daily technical assistance for truck body builders. Phone: 877-840-4338 Fax: 313-594-2633 Web Site: www.fleet.ford.com/truckbbas E-Mail: [email protected] F-Super Duty Class “A” Chassis Motorhome Liaison: 313-337-6520 Fax: 313-621-8032 • MODIFIED VEHICLE ENGINEERING & QUALITY PROGRAMS Responsible for qualifying the engineering process control capability of final stage manufacturers under these programs: – QVM-Ambulance Quality Program – QVM-Motor Home & Transit Bus Quality Program – Conversion Van Quality Program – F-Series Quality Program – Adaptive Mobility Quality Program • MVE SHIP-THRU SECTION Responsible for qualifying the engineering process control capability of companies that up-fit vehicles in the ship-thru process. Assembly Plant Job #1 Timing 2002 Model Job #1 Vehicles Assembly Plant F-150 Regular and SuperCab Norfolk Assembly Plant Kansas City Ontario Truck Plant 7/30/01 8/20/01 8/27/01 F-150 SuperCrew Kansas City 8/20/01 Super Duty F-Series F-350/450/550 Chassis Cab And Pickup Box Delete: F-250/350 Pickup: F-250/350 Pickup: F-650/750: Kentucky Truck Plant Kentucky Truck Plant Cuautitlan, Mexico Cuautitlan, Mexico 7/16/01 7/16/01 8/13/01 8/27/01 F-53 Class A Motor Home Chassis 15,700, 18,000, 20,500-lb. GVWR: 22,000lb. GVWR: Detroit Chassis Plant Detroit Chassis Plant 7/26/01 7/26/01 Excursion Kentucky Truck Plant 7/16/01 Expedition Michigan Truck Plant 7/23/01 E-Series (except E-550) E-550 Super Duty Cutaway Lorain Assembly Plant Lorain Assembly Plant 7/23/01 1st Quarter 2002 1 F-150 2002 MAJOR PRODUCT FEATURE CHANGES ■ MODEL/TRIM: • New King Ranch trim package available on SuperCab. • Harley Davidson F-150 features 5.4L Supercharged 2V engine. “Supercharged” added to fender/tailgate badges; revised grille (larger quasi-billet chrome bars with larger spacing between bars), and flame accents added to the exterior upper tape stripe and interior front and rear console covers (Job #1 1/7/02) • New FX4 Off-Road Equipment Group features 17" 5-Spoke Cast Aluminum Wheels, “FX4 Off-Road” decal, skid plates and white colored branded Rancho shock absorbers. Also includes color-keyed grille insert, wheel lip moldings and front bumper top cap (Dark Shadow Gray with XLT and Arizona Beige or Silver with Lariat). Matching lower two-tone and unique paint break stripe is optional. ■ POWERTRAIN/CHASSIS: GVWR/GCWR • 6,050 lbs. GVWR replaces the 5,600 lbs. GVWR (Regular Cab) and the 6,000 lbs. GVWR (SuperCab) as standard with 4.2L engine (Optional 6,000 lbs. GVWR Payload Package No. 2 available last year on Regular Cab is also cancelled). • 7700 Payload Group renamed 7700 Lb. Payload Group A (7,700 lbs. GVWR/3.73 axle/13,500 lbs. GCWR/8,800 lbs. max. trailer weight). New 7700 Lb. Plus Payload Group B is available on 139" wheelbase Regular Cab and Supercab 4x2 models only and includes Group A content plus upgraded 22-plate auxiliary transmission oil cooler, Class III Trailer Tow Group and 4.10 limited slip axle (7,700 lbs. GVWR/4.10 axle/15,000 lbs. GCWR/8,800 lbs. max. trailer weight). Engine • Heavy Duty Electrical/Cooling Group cancelled. 72 amp.-hr. battery and auxiliary automatic transmission oil cooler (number of plates varies by application) are included with Class III Trailer Tow Group and 7700 Lb. Payload Groups A and B. The 7700 Lb. Payload Groups also include an upgraded radiator with 1.42" core thickness. • 4.6L engine includes new integrated air fuel module (IAFM), to include air cleaner assembly, air filter, mass air flow sensor and AIT sensor to meet 2002 emissions requirements. • 6 rib serpentine belt replaces 8 rib belt/pulley (except Lightning and Harley Davidson). Tires/Wheels • New spare tire lock is standard (late availability). ■ EXTERIOR: Paint and Trim • Colors added are Dark Shadow Grey and True Blue. Color availability expanded are Estate Green available on XLT and Lariat and Toreador Red available on Lariat. Colors deleted are Wedgewood Blue and Island Blue. ■ INTERIOR: Comfort and Convenience • Interior revisions to meet FMVSS 201Occupant Protection in Interior Impact: New windshield header assembly and A-pillar inner (similar as 2002 Expedition); New grab handles (added foam); New headliner assembly (added foam), coat hooks, sun visor attaching brackets and safety belt with adjustable D-ring; New side rails, 2 F-150 2002 MAJOR PRODUCT FEATURE CHANGES (continued) front and rear door and rear quarter trim (adding ribbing and cartridges to enhance occupant protection (Job #1 1/2/02). • Air Conditioning is standard with XL trim (optional with Work Truck Group). • New electronic automatic temperature control air conditioning is standard on SuperCrew Lariat and King Ranch models (late availability on SuperCab). • New “Fuel Cap Loose” warning light. 3 F-250/350/450/550 Super Duty 2002 MAJOR PRODUCT FEATURE CHANGES ■ MODEL/TRIM: • New F-450-550 SuperCab DRW 161.8" WB/60" Cab-to-Axle (CA) Chassis Cab models. With the availability of SuperCab on F-450 and F-550, this popular cab configuration is available on all F-Series from F-250 to F-750. - Back seats can accommodate 3 passengers - Also suitable for stowage of tools or cargo • Pickup box delete option is now available on long wheelbase (8-foot box) F-350 SRW models. ■ POWERTRAIN/CHASSIS: GVWR/GCWR • Conventional towing ratings increased to a maximum of 12,500 lbs. (from 10,000 lbs.) with 6.8L V-10 (4.30 axle) and 7.3L Diesel engines (late 2001 MY change). • Maximum GVWR increased to 12,500-lbs. (from 11,500-lbs.) on 49-states F-350 DRW Pickup models with 7.3L Diesel engine (172.4” WB Crew Cab remains at 11,500-lbs. GVWR; California remains at 11,000-lbs. GVWR). Conventional trailer tow ratings increased to a maximum 23,000-lbs. GCWR/13,500-lbs. trailer weight (from 20,000-lbs. GCWR/12,500-lbs. max. trailer weight) on F-350 DRW Pickup models with 6.8L V-10 (4.30 axle) and 7.3L Diesel (4.10 axle) (Effective December, 2001). Axles • Synthetic oil lubrication included with all 30,000-lb. GCWR option packages (all other applications include mineral oil lubrication). Engine • 6.8L Bi-fuel (Gas/LPG) Vehicle Program is canceled. • G05 Hybrid/OA long life coolant (100K miles) standard for all applications. Electrical • 6G 130 ampere/1950 watt alternator standard for all engines. Dual 130 ampere/ 1950 watt alternators optional with 7.3L diesel engine. • 7/4 pin trailer towing connector revised to 7 pin connector. • New interior power distribution junction box combines the power distribution box with the junction box and places all fuses under the instrument panel. Fuel • Dual Fuel Tank option (19-gal. midship/40-gal. aft-of-rear axle) is available on DRW Chassis Cabs with 7.3L V-8 Diesel. Includes new instrument panel mounted tank selector control switch. Greater fuel capacity means increased range —fewer stops. That’s the idea behind the new dual fuel tank option. A tank selector control switch is conveniently mounted on the instrument panel. Transmission • ZF-650OD 6-speed manual overdrive transmission replaces the 5-speed manual overdrive transmission as standard with 5.4L V-8 and 6.8L V-10 engines. Suspension • Auxiliary rear springs are now standard on all models (Late 2001 MY change) Tires • New 225/70R19.5F traction tire is available on 4x2/4x4 in the Traction Package or on 4x4 in the Max Traction Package on F-450-550 models. 225/70R19.5F allterrain tire will be phased out in January, 2002. 4 F-250/350/450/550 Super Duty 2002 MAJOR PRODUCT FEATURE CHANGES (continued) ■ EXTERIOR: Lighting • New “jeweled” single beam complex reflector headlamp with separate park and turn lamps are standard with XLT, Lariat and Lariat LE. Mirrors • Trailer tow mirrors include new forward fold feature. The popular manual telescoping/power glass trailer tow mirrors now fold both forward and backward. Paint and Trim • Colors added are Arizona Beige and Dark Shadow Grey. Colors deleted are Harvest Gold and Bright Amber. • Two new exterior color schemes for Lariat LE include Ebony monotone exterior or Ebony/Dark Shadow Gray/Ebony two-tone exterior. • Three new two-tone tape break stripes/color combinations. ■ INTERIOR: Comfort and Convenience • New roof/headliner mounted ride handle for the front seat outboard passenger is standard for all cab styles. Crew Cab also includes standard L.H./R.H. ride handles for rear seat outboard passenger seating positions (Handles are same as Excursion). • XLT cloth sun visors with L.H. map strap and R.H. uncovered mirror made standard on XL models. • New larger Lariat overhead console includes sun glasses bin, garage door opener bin and trip computer with distance-to-empty (deleted with dual fuel tanks), outside temperature and compass displays (Similar to F-150 console). The new, larger Lariat Overhead Console extends this popular feature to the F-250 through F-550 range, adding even more storage convenience. • SuperCab rear door trim panels are revised to include new standard L.H./R.H. cup holders for 12-oz. cans and 20-oz. bottles. SuperCab rear seat passengers can now enjoy the convenience of a cup holder, integrated into the rear door trim panel on both right hand and left hand sides. • New Security Lock Group is optional on XLT and standard on Lariat and Lariat LE and includes Remote Keyless Entry and new Auto Lamp and Auto Lock/Relock features. Instrumentation • Transmission fluid temperature gauge replaces battery gauge with automatic transmission applications (Battery warning light remains). The transmission fluid temperature gauge allows the driver to monitor fluid temperature and alter usage conditions accordingly. Seating • New XL cloth seat trim materials are “Hopsack” side facings/bolsters with “Links” inserts (replaces Fargo/Summit cloth, sew style carryover). • New sew styles and foam for XLT, Lariat and Lariat LE Regular Cab and Crew Cab seats for comfort and appearance. New XLT cloth seat trim materials are ‘Elliott” side facings/bolsters with “Bazaar” inserts (replaces Beacon/Dillon cloth). • Inboard arm rests added to front and rear Captain’s Chairs. • Crew Cab 6-way power adjustable front outboard passenger seat is optional on XLT and standard on Lariat and Lariat LE. 5 ELECTRICAL WIRING POWER TAKE-OFF CIRCUIT INSTALLATION The Body Builder must provide a PTO Circuit to alert the PCM to PTO operation. Failure to provide this circuit may result in erroneous emission codes, and inadvertent illumination of the “Service Engine Soon” light during PTO operation. Circuits 294 (WH-LB) is located in the center of the instrument panel, labeled “Power Take-Off Circuit” and the circuit 322 (LB-Y) is located to the right of the parking brake labeled “Customer Pass-Thru/PTO and CTO Circuits” (see Figure A). They are near the customer pass-thru circuits, and are blunt-cut with shrink wrap tubing over the cut ends. They are easier to access from the front of the instrument panel (IP) by removing the access panel below the steering column (4 quarter-turn fasteners). Splice circuit 294 (WH/LB) to the body builder provided wire that connects to the positive side of the PTO indicator switch or PTO control relay. Splice circuit 322 (LB-Y) to the body builder provided wire that connects to the positive (switched) side of the PTO indicator light. (See Figure C1). In electrically-actuated PTO systems, must be relay isolated from the circuit containing the solenoid or PCM DAMAGE COULD RESULT (See Figure C2). FIGURE A - VIEW UNDER DASH — SUPER DUTY F-SERIES FIGURE C1 - SUPER DUTY F-SERIES FIGURE C2 - SUPER DUTY F-SERIES 6 Power Distribution Junction Box For the 2002 Model Year, Super Duty F-Series (F-250/350/450/550) vehicles have had extensive electrical changes. All fuse numbering has changed with the combination of the Power Distribution Box and the Junction Box into the Power Distribution Junction Box (PDJB). The PDJB is found under the dash, below the steering wheel and behind the modesty panel. Another change has been the addition of relays to Trailer Tow Stop/Turn Circuits 52 (Yellow) and 64 (Dark Green). This change will require SUB installers, who have used the trailer tow connector to connect their SUB, to rethink their connection. The relay isolation of circuits 52 and 64 require the connection of some load to the Ford Stop/Turn connectors or the turn signals will flash as if a bulb were burned out. Either connect your SUB Stop/Turn signals to the Ford Stop/Turn signal connectors or connect a resistive load to each of the connects. Trailer Tow Second Unit Body Wiring Tap Schematic – Super Duty F-Series 7 Changes To Circuits Check your fuses and circuits for the 2002 Model Year. DO NOT ASSUME that there are no changes for the 2002 Model Year F-250/350/450/550 vehicles. The DRL control circuits are new for 2002. The elimination of the GEM has also brought about many electrical changes. Check your circuits and your fuse numbers and if you have questions call the Ford Truck Body Builders Advisory Service at (877) 840-4338 or E-mail us at [email protected]. Contact us before applying power to any circuit you are unsure about. This may take more time now, but it will save you from damaging the Ford vehicle’s electrical system. Take the time to contact us and you will save more than time. Electrical Wiring Schematic for Adding Lights or Electrical Devices 8 F-650 Super Duty 2002 MAJOR PRODUCT FEATURE CHANGES ■ MODEL/TRIM: • Lo-Profile Package (July 2001 Introduction) – 8.5" frame – 19.5" 8-hole disc wheels – 245/70R 19.5G tires - G159 front - G124 rear – Tuned springs and shocks – Improved braking for lighter GVW’s • Rescue Package (available December, 2001) – Lo-Profile 20,000 lb. GVWR – 108" CA – HAS 120 single axle air suspension with dump valve – Hendrickson system Dump valve provides “kneeling” feature – 225 hp Cummins engine with Allison 2400 5-speed automatic transmission – 270 amp alternator – Hydraulic brakes – 18K GVWR available ■ POWERTRAIN/CHASSIS: GVWR/GCWR Engine • 6 rib serpentine belt replaces 8 rib belt/pulley. • Caterpillar 3126 Low Emission Vehicle (LEV) available • Allison AT545 automatic transmission now standard w/Cummins 210 HP/520 lbs.ft. torque • Aluminum wheels (Lo-Pro) available as stand-alone option ■ EXTERIOR: Paint and Trim • Chrome grille and chrome headlight bezels available as a stand-alone option • Telescoping mirrors available ■ INTERIOR: Trim • Medium Flint interior replaces Medium Graphite 9 F-750 Super Duty 2002 MAJOR PRODUCT FEATURE CHANGES ■ MODEL/TRIM: • New F-750 tractor package. Targeted at the beverage industry and single axle tractor applications – 158" WB Regular Cab – 179" WB SuperCab. – Available with Caterpillar and Cummins diesel engines, and MD Automatic transmission ■ POWERTRAIN/CHASSIS: GVWR/GCWR • 30,000 lb. GVWR - Allison AT545 Automatic transmission is now standard with Cummins 210hp/520 lb.ft. torque. This replaces the manual transmission as standard. • 33,000 lb. GVWR - Allison MD-3060CR automatic transmission now standard with Caterpillar 210 hp/605 lb. ft. torque. This replaces the manual transmission as standard. Engine • 6 rib serpentine belt replaces 8 rib belt/pulley • Caterpillar 3126 Low-Emission Vehicle (LEV) available EXTERIOR: Paint and Trim • Chrome grille and chrome headlight bezels available • Telescoping mirrors available INTERIOR: Trim • Medium Flint interior replaces Medium Graphite • Tilt wheel available on 33K GVWR 10 F-53 Class A Motorhome Chassis 2002 MAJOR PRODUCT FEATURE CHANGES ■ MODEL/TRIM: • Front GAWR increased to 7,500 lbs. • Rear GAWR increased to 14,500 lbs. • Shocks and springs retuned to match higher GAWR ■ POWERTRAIN/CHASSIS: GVWR/GCWR • 22,000 lb. GVWR and 4-Wheel/4-Channel ABS • Visual differences between 20,500 lb. vs. 22,000 lb. GVWR — 22,000 lb. GVWR has: – Tape Tag on axle tube with P/N – white and blue lettering – Paint dot on rear of axle housing – Springs have P/N painted in green on top leaf – Bar coded incomplete vehicle label has GVWR listed on it Engine • 6 rib serpentine belt replaces 8 rib belt/pulley 11 E-Series Van / Cutaway / Stripped Chassis 2002 MAJOR PRODUCT FEATURE CHANGES MODEL/TRIM: New AC Scroll Compressor Standard Features Include: • Tilt Steering Wheel • Speed Control (Standard on Recreational Vans/Optional on Commercial Vans) • Back Lit Switches • Rear Chrome Step Bumper (Contour Chrome Bumper - Optional) • Rear Vinyl Floor Covering (Maslite) w/delete option POWERTRAIN/CHASSIS: Rear Axle • New 4.56 Limited Slip (LS) Axle (5.4L NGV, 6.8L) - E-450 Cutaway • New 4.10 Limited Slip (LS) Axle (7.3L Diesel) - E-450 Cutaway Engine • New Fuel Pump - Turbine Type Pump (Replaces Rotor) • AC Scroll Compressor New AC Scroll Compressor helps increase durability. Location has not changed, but plumbing connections are all-new for 2002. New Base Mirror (Van) • New Aluminum Aux. Heat & A/C Tubes Lines • New Dual Idler Bearings (FEAD) - 7.3L Diesel New Dual Idler Bearings help improve high mileage life • Improved Belt Life & Noise on All Engines (Orion Material) • New Engine Oil Cooler - 6.8L • New Nickel Plated Spark Plug Shell • New Stainless Steel Engine Cup Plug • Improved NVH - 4.6L, 5.4L, 6.8L - Valley Stuffer • New Anti Splash Baffle in Master Cylinder Frame New Telescopic Mirror (Cutaway) • New E-Coating on Frames (Replaces Wax Coat/Paint) Suspension • New Upper Ball Joint Wear - Added Grease Plugs. • New Lower Front Shock Bushing Material (Urethane) EXTERIOR: New Brake Caliper Shield 3 Dome Lights (Standard) Mirrors • New Exterior Mirrors (First Quarter, 2002) Cutaway features Standard Trailer Tow Mirror similar to the one featured on F-Series. The E-Series Van with Trailer Tow Option will also receive a new base mirror at mid-model year. Paint and Trim • New Wheel Covers Wire Diameter & Dimension Controls • New Caliper Shield (Stone Pecking) (E-350, E-450 Only) • Sound Deadening and Sealing • Thicker Spray on PVC in Wheel Wells • Extensive Body Sealing • New Front Door Hinge Bushings (Sprayed Teflon vs. Bonded) • Running Boards Optional on Vans and Cutaways 12 E-Series Van / Cutaway / Stripped Chassis 2002 MAJOR PRODUCT FEATURE CHANGES (continued) INTERIOR – Comfort and Convenience (continued): INTERIOR: New Dual Idler Bearings replace former bearings for improved high mileage life OLD NEW New Valley Stuffer improves NVH Comfort and Convenience • New Illuminated Rear Aux. Heat & A/C Switch • New CD6 Player - Optional w/Dual Media • New Dome Light On/Off Switch (Rear Door) and 3 Lamps Standard • Diesel Engine Cover (4.2L, All E-Traveler & 7.3L Diesel) • Dash Panel Sound Absorber Front • Carpet - Added Binder and Upgraded Padding • Wheel House Covers Added • Rear Vinyl Floor Covering (Maslite) - Upgraded padding. • New Dash Cowl Reinforcement—Stiffer I/P cross car beam. • Grab Handle - A-pillar/passenger side. • Floor Covering, front & rear (Std.) • Under Seat Storage - passenger side • Armrest - inboard, all front seats Door Trim • New front door trim panels (Late Availability) Instrumentation • New Low Fuel Warning Light - I/P Cluster. • New Speed Control “On” Indicator Light - I/P Cluster. Seating • New Seat Material - Improved vinyl (Stockton 2 Directional). • New Seat Material - Increased foam density. • New Seat Material - Increase flex mat wire gage/added hook. Instrument Panel Sound Absorber (NVH) New Front Door Trim Panels New Instrument Panel Reinforcement 13 E-550 Cutaway (late availability) 2002 MAJOR PRODUCT FEATURES MODEL/TRIM: • Five wheelbase lengths: 159.5", 177.5", 191.5", 209.5", 233.5" Five wheelbase lengths means E-550 will be the vehicle of choice for a greater range of commercial applications. POWERTRAIN/CHASSIS: Roof marker Lights (Optional) Telescopic Mirror GVWR/GCWR • 17,500 lbs. and 19,000 lbs. GVWR availability. • 20,000 lbs. max. GCWR The new 17,500 and 19,000 lbs. GVWR allows E-550 to accommodate larger payloads. GAWR • 6,000 lbs. front; 11,500 lbs. or 13,500 lbs. rear. Engine • 6.8L V10 gas or 7.3L diesel engine. (Diesel 49 states only). Fuel Tanks • 55 gallons Aft-of-axle (Standard) Tires/Wheels • 19.5 in. wheels and tires • Steel wheels (Standard) • Polished aluminum wheels (Optional) Transmission • 4-Speed electronic automatic with overdrive (4R100) Maneuverability Reduced turning diameter vs. E-350/E-450 Tighter turning diameter makes E-550 a perfect vehicle for moving about city streets for local pick up and delivery. EXTERIOR: Running Boards (Std.) Wheel Lips (Std.) Lighting • Roof marker lights (Optional) Mirrors • New trailer tow mirrors (Standard); Mirror Delete Option available New standard manually-telescoping trailer tow mirrors feature electrically adjusted glass and are perfect for 96"-wide second-unit bodies. Trim • Running boards (Standard) Standard running boards make ingress and egress easier. • Wheel lips (Standard) • New grille and lower bumper fascia Distinctive new Super Duty grille and lower bumper fascia add to the overall good looks of E-550 Distinctive Grille and Lower Bumper Fascia 14 E-550 Cutaway (late availability) 2002 MAJOR PRODUCT FEATURES (continued) Interior: Comfort and Convenience • Front Door Trim Panel Front door trim with convenient storage pocket • Premium Plus CD6 Radio (Optional) • Tilt Wheel (Standard) • Dual Media Radio Provides in-dash single CD player and cassette • Speed Control (Optional) Functional: New Front Door Trim Panels Stiffer Frame Flat Frame Design Common frame section & hour-glass shape Crossmember Frame • Hour-glass design with common frame section around rear axle Common frame section with hour-glass shape and flat frame design to facilitate ease of body installation. • Multi-piece Construction • Flat Frame Design • Stiffer frame (than E-450) • Removable engine crossmember for servicing front engine oil pan Front Axle/Suspension • Solid forged I-beam front axle • Tapered leaf springs • Gas shocks with 35 mm bore and 580 mm extended length • 36 mm diameter torque bar Steering • Haltenberger type steering geometry • Steering gear, heavy duty-high output • Wheel cut angle, 40 degrees Rear Axle/Suspension • Axle, Dana 135 Medium Duty (13,500 lbs. capacity) • Tapered leaf springs (11,500 lbs. standard, 13,500 lbs. optional) • Gas shocks with 35 mm bore and 703 mm extended length • 31 mm diameter torque bar Front Suspension 15 Electrical Wiring CUSTOMER ACCESS CIRCUITS This chart contains the changes and additions to the Customer Accessible Circuits for 2002 E-Series vehicles. Changes to other circuits may have occurred in circuits not designated as Customer Access Circuits. For this information refer to the 2002 Ford E-Series Wiring Diagrams Book available from Helm, Inc. (800) 782-4356 or www.helminc.com. CIRCUIT CHART Circuit Number 2 3 14 22 43 49 52 53 59 64 206 511 648 867 868 962 963 Color Code WH/LB LG/WH BR LB/BK DB O Y BK/LB LG/YE DG W LG WH-PK DB GY/R BR-W BK-LG Wire Gauge 18 18 18 12 12 12 16 18 18 16 16 18 18 12 12 16 16 Functional Description Right turn signal Left turn signal Marker lamp feed to electric brake controller Trailer brake controller or B + feed Electric trailer brake controller Relay feed ignition run Fused left hand stop/turn Courtesy lamps Courtesy switch feed Fused right hand stop/turn Ground Center high mount or lamp feed stop Clean tach output (CTO) Customer pass-thru circuits Customer pass-thru circuits Relay feed marker lamps Relay feed backup lamp THE “CHMSL” ELECTRICAL CONNECTION FOR A STRIPPED CHASSIS IS PROVIDED IN A DETAILED SCHEMATIC, WHICH IS PACKAGED WITH THE BODY BUILDER ELECTRICAL CONNECTORS TO INSTALL “CHMSL”, UNWRAP TAPE FROM HARNESS IN THIS AREA AND REMOVE JUMPER CONNECTION TO EXPOSE THE “CHMSL CONNECTOR” FRONT OF VEHICLE 16 Excursion 2002 MAJOR PRODUCT FEATURE CHANGES MODEL/TRIM: • New exterior colors: True Blue (replaces Deep Wedgewood Blue), Aspen Green (replaces Dark Satin Green), Medium Wedgewood Blue - XLT only (replaces Medium Steel Blue), Mineral Gray - Limited only (replaces Arizona Beige), Silver Birch - XLT only (replaces Silver). • Revised Fleet Special Service Package – Power heated, sail mounted exterior mirrors – Seat configuration changes • Deleted optional Limited Feature Vehicle (No Boundaries Package) POWERTRAIN/CHASSIS: Engine • New G05 Hybrid/OA long life (100K mile) engine coolant Electrical • 130 amp./1950 watt 6G alternator w/central load dump capability (CLD) now standard on gas engines, replacing HD alternator • Heavy Duty Trailer Tow Package revised to eliminate 7/4 way adapter • New interior power distribution junction box combines the power distribution box with the junction box and places all fuses under the instrument panel EXTERIOR: Lighting • Single beam jeweled headlamps replace aero halogen headlamps. • Modified position and parking light assembly. Mirrors • Fold forward feature added to optional Telescoping Trailer Tow Exterior Mirrors Paint and Trim • Deleted Chestnut exterior color • Medium Platinum XLT bodyside cladding replaces Medium Flint • Chrome insert added to Limited bodyside cladding • New Paint Stripe Colors: Mocha (replaces Saddle), Medium Dark Charcoal (replaces Blue) Windshield Wipers • New ‘smart” windshield wiper motors (front and rear) INTERIOR: Comfort and Convenience • Medium Flint interior color replaces Medium Graphite (XLT only) • Revised Comfort Group • Revised Convenience Group • 12 oz. Lanier carpet replaces 12 oz. Midway • 12 oz. Lanier floor mats replace 12 oz. Midway on XLT. • Fixed accelerator and brake pedals now standard on XLT • Standard auto door locks • Integrated DVD System replaces Video Cassette Player in Rear Entertainment System (Late Availability) • Rear Seat Entertainment System now optional on XLT 17 Excursion 2002 MAJOR PRODUCT FEATURE CHANGES (continued) Instrumentation • Standard Electronic Automatic Temperature Control (EATC) on Limited. • US Hybrid III Instrument Cluster replaces US Instrument Cluster • Deleted Mini-overhead console • New optional Ultimate Group on Limited Seating • New seat sew styles • Elliott cloth bolster seat material replaces Beacon • Nudo leather replaces “sheared” nudo leather on Limited • New optional 2nd row bucket seats on Limited • Extended lumbar added to all 1st row captains chairs and 40/20/40 bench seats • Inboard arm rests on captains chairs have increased length 18 Expedition 2002 MAJOR PRODUCT FEATURE CHANGES MODEL/TRIM: Revised Eddie Bauer Premier Package. POWERTRAIN/CHASSIS: Axles • 3.55 rear axle ratio replaces 3.31 on 4x2 w/4.6L engine. • 3.73 rear axle ratio high altitude restriction removed on 4x4 w/5.4L engine. Engine • 6-rib serpentine belt replaces 8-rib belt/pulley. • Added cylinder block ribbing to 5.4L engine for NVH improvement. • New G05 Hybrid/OA long life (100K mile) engine coolant. • Wisconsin added to list of U.S. States (7 total) requiring engine block heater. Available through FCSD in other states. Steering • Assist power steering replaces variable assist. EXTERIOR: Paint and Trim • Deleted exterior colors: Dark Highland Green, Dark Toreador Red, Deep Wedgewood Blue, Estate Green. INTERIOR: Seating • Optional Rear Seat Entertainment System on both XLT & Eddie Bauer. 19 Tire Pressure Awareness Label Ford Motor Company is equipping all E-Series and F-Super Duty models with a Tire Pressure Awareness label that will be located inside the fuel door. For incomplete vehicles without fuel doors, the label will be placed in the incomplete vehicle package. The label is to be installed by the Final Stage Manufacturer in a noticeable location near the fuel tank fill location. This label contains tire size and front/rear pressures. The label must be applied to a clean surface. E-350 F-Series E-450 Incomplete Vehicle 20 Truck Body Builders Advisory Service Website (http://www.fleet.ford.com/truckbbas) Hot Off The Press: Displays latest up-to-date publications available to Body Builders Truck Support Contacts: Displays frequently requested phone and fax numbers These may be useful in answering your truck-related questions. Body Builder’s Layout Book: Provides access to and order capability for Body Builder Layout Book Bulletins: Displays the latest Bulletins relative to CVQP, QVM and MVE programs 21 OBTAINING PUBLICATIONS Ford Truck Body Builders Layout Book Order and access via www.fleet.ford.com/truckbbas. Incomplete Vehicle Manual Access at www.fleet.ford.com/truckbbas. Ford Recreation Vehicle and Trailer Towing Guide The guide covers cars and light trucks, and includes trailer and camper weight ratings and the list of vehicles suitable for flat-towing. A copy can be obtained by contacting the Ford RV Information Service at (800) 2457343, leave name and shipping address, or Fax to (248) 936-3300. Service Publications The “Ford Technical Publications Catalog” list the service publications available, and includes pricing, an order form, and a mailer. Contact Helm, Inc. at 800-782-4356. Useful publications include “Truck Wiring Diagrams” and the “Service Specifications” book. Body Builder Quality Bulletins Body Builder Quality Bulletins provide key information to assist Body Builders in interfacing with a Ford chassis: • Conversion Van Quality Program (CVQP) Bulletins • Qualified Vehicle Modifier (QVM) Bulletins • Modified Vehicle Engineering (MVE) Bulletins These bulletins can be accessed via the web at www.fleet.ford.com/truckbbas. 22 IMPORTANT PHONE NUMBERS AND WEB SITES INTENDED FOR GENERAL USERS & CUSTOMERS OF COMPLETED VEHICLES Ford Customer Assistance Customer Assistance Center: 800-392-3673 Roadside Assistance Center: 800-241-3673 Web Site: www.ford.com Ford RV (Customer Assistance Center) To locate the nearest RV service center: 800-444-3311 INTENDED FOR FINAL STAGE MANUFACTURERS & VEHICLE MODIFIERS Ford Truck Body Builders Advisory Services (BBAS) Truck: 877-840-4338 Fax: 313-594-2633 Web Site: www.fleet.ford.com/truckbbas E-Mail Address: [email protected] List of Ford Pool Accounts and Qualified Vehicle Modifiers www.fleet.ford.com/truckbbas Click on “Specialty vehicles” on the navigation bar and select the desired vehicle type. F-Super Duty Class A Motorhome Chassis Liaison 313-337-6520 Fax: 313-621-8032 Ford Alternative Fuels Information Vehicle models available, list of authorized Ford dealers, and Leaf & Road Newsletter. 877-ALT-FUEL (877-258-3835) Ford Component Sales 734-523-5702 Fax: 734-523-5917 E-Series Aft-of-Axle Fuel Tank Kit (gasoline and diesel) TDM, Inc.: 800-540-3913 Alternate: 734-458-9100 Fax: 734-458-9118 Dealer Special Order, DSO Fleet Sales 1-800-34-FLEET Select #4 23 North American Truck Special Vehicle Engineering Department Information herein was correct when approved for printing. Ford Motor Company reserves the right to discontinue or change at any time, specifications, designs or programs without incurring obligation. SVED-09-01 August, 2001 AOC 16126 Litho in USA