Body Builders Layout Book
Contents
1. PICKUP BOX REMOVAL PICKUP BOX REMOVAL Design Recommendations Models amp Wheel Tire Data www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS INDEX 2013 MODEL YEAR 2 PICKUP BOX REMOVAL PART I Introduction The following information is presented in three parts for vehicle alterers who intend to remove pickup boxes from certain Super Duty F Series pickup trucks and install aftermarket second unit bodies on these vehicles Part details those Super Duty F Series pickup models that may be altered by removal of the pickup box and installation of aftermarket second unit bodies and indicates where specific questions should be directed Part Il provides information concerning the obligations and responsibilities of vehicle alterers with respect to United States and Canada Motor Vehicle Safety Standards F CMVSS Part Ill provides information for vehicle alterers with respect to United States California and Canada exhaust emissions evaporative emissions and RFI requirements and California requirements with regard to fuel vapor Recovery Vehicle alterers who intend to modify vehicles as described above may use the information and conditions provided herein to assist them in determining whether modified vehicles comply with applicable regulatory requirements Alternatively the vehicle alterer may desir2. 10 000 340 24 0 7819 8608 F 350 4x4 141 8 10 000 10 000 340 24 0 7819 8608 F 350 4x2 141 8 10 200 10 400 340 24 0 SuperCab F 350 4x4 141 8 10 400 10 800 340 24 0 F 350 4x2 158 0 10 000 10 000 380 24 0 7819 8608 F 350 4x4 158 0 10 000 10 000 380 24 0 7819 8608 F 350 4x2 158 0 10 200 10 600 380 24 0 F 350 4x4 158 0 10 600 11 000 380 24 0 F 350 DRW 4x2 158 0 12 400 12 800 420 24 0 F 350 DRW 4x4 158 0 12 600 13 000 420 24 0 F 250 4x2 156 2 9400 9800 340 24 0 7819 8608 F 250 4x4 156 2 9600 10 000 340 24 0 7819 8608 F 250 4x2 172 4 9600 10 000 380 24 0 7819 8608 F 250 4x4 1724 9800 10 000 380 24 0 7819 8608 F 350 4x2 156 2 10 000 10 000 340 24 0 7819 8608 F 350 4x4 156 2 10 000 10 000 340 24 0 7819 8608 F 350 4x2 156 2 10 200 10 600 340 24 0 F 350 4x4 156 2 10 600 11 000 340 24 0 a Crew Cab F 350 4x2 172 4 10 000 10 000 380 24 0 7819 8608 F 350 4x4 172 4 10 000 10 000 380 24 0 7819 8608 F 350 4x2 1724 10 400 10 800 380 24 0 F 350 4x4 1724 10 800 11 200 380 24 0 F 350 DRW 4x2 156 2 12 400 12 800 420 24 0 F 350 DRW 4x4 156 2 12 600 13 000 420 24 0 F 350 DRW 4x2 172 4 12 600 13 000 420 24 0 F 350 DRW 4x4 172 4 12 600 13 000 420 24 0 a Vertical height measured from the top surface of
3. affixed to the driver s door latch pillar of the pickup truck by Ford Motor Company must not be removed For altered vehicles in Canada the vehicle alterer is required to affix a label containing the information shown in the Safety Emissions section NOTE A vehicle alterer may be a manufacturer according to the definition of manufacturer contained in the Canadian Motor Vehicle Safety Act PART Ill Information concerning United States and Canada Exhaust Emissions Evaporative Emissions RFI and Noise and California Fuel Vapor Recovery Requirements Refer also to pages within the Safety Emission section NOTE The information herein is provided as guidance only it is the responsibility of the vehicle alterer to assure compliance of the altered vehicle with the applicable emission requirements A copy of the appropriate Ford Truck Owner s Guide and Warranty Facts Booklet is installed in the altered pickup truck prior to sale to the ultimate purchaser in order to provide emissions system information and maintenance schedules NOTE Whether Ford Motor Company or the alterer is responsible for emission warranty claims depends on among other things whether the vehicle failed to comply with applicable warranty provisions because of modifications made by the alterer or because of the original design and manufacture of the vehicle Questions concerning requirements and policies with respect to alterers of completed vehicl
4. or delivered for sale or registered in California unless the altered vehicle is certified by the California Air Resources Board pursuant to all applicable emissions requirements The vehicle alterer is responsible for obtaining such certification Questions regarding these requirements should be directed to your legal counsel or the California Air Resources Board 8 PICKUP BOX REMOVAL PICKUP BOX REMOVAL ALTERATIONS MODELS amp WHEEL TIRE DATA TABLE A SUPER DUTY F SERIES MODELS AVAILABLE FOR PICKUP BOX REMOVAL Second Unit Body Limits Max Maximum Complete GVWR Ib Weight Heighta Vehicle UVW Ib cl WB Min Cg b 6 2L 6 7L Body Style Model Drive in 6 2L 6 7L 1b in Gasoline Diesel F 250 4x2 137 0 9000 9400 380 17 6 7819 7749 F 250 4x4 137 0 9200 9600 380 17 6 7819 7749 F 350 4x2 137 0 10 000 10 000 380 17 6 7819 7749 F 350 4x4 137 0 10 000 10 000 380 17 6 7819 7749 Regular Cab F 369 4x2 137 0 10 100 10 200 380 17 6 F 350 4x4 137 0 10 200 10 600 380 17 6 F 350 DRW 4x2 137 0 12 000 12 400 420 24 0 F 350 DRW 4x4 137 0 12 200 12 600 420 24 0 F 250 4x2 141 8 9200 9600 340 24 0 7819 8608 F 250 4x4 141 8 9400 9800 340 24 0 7819 8608 F 250 4x2 158 0 9400 9800 380 24 0 7819 8608 F 250 4x4 158 0 9600 10 000 380 24 0 7819 8608 F 350 4x2 141 8 10 000
5. CHMSL on the back of the cab another CHMSL must be added Rear Side Marker Lamps Front and Rear Identification Lamps for vehicles over 80 inches in width Front and Rear Clearance Lamps for vehicles over 80 inches in width The items of lighting equipment including wiring and power supply on the cab of the pickup truck must not be removed modified replaced or altered Further the second unit body installed by the vehicle alterer must not impair the visibility and conformity to the photometric requirements of the lamps and reflective devices installed on the cab of the pickup truck 2013 MODEL YEAR 2 The weight in pounds of the Second Unit Body SUB installed must be within the range specified in Table A corresponding to the particular pickup truck model and not greater than the weight in pounds calculated using the following formula SUB WEIGHT LIMIT Unloaded Vehicle Weight UVW Original Equipment Manufacturer OEM Curb Weight Pickup Box Options Removed Super Duty F Series Step Bumper 74 Ib Pickup Box see Table A Spare Wheel and Tire see Table B NOTES 1 Standard 105 applies to vehicles with a GVWR over 3500 Kg 7716 Ib 2 Limit CGv as specified in the Incomplete Vehicle Manual IVM 3 For vehicles with a GVWR of 10 000 Ib or less and an unloaded vehicle weight of 5500 Ib or less 4 Applicable to vehicles with a GVWR of 10 000 Ib or l
6. the Contact Us tab Models Available for Pickup Box Removal The Super Duty F Series may be altered by removing the pickup box and installing aftermarket Second Unit Bodies SUBs Limitations on the Second Unit Bodies SUBs that may be installed as well as other vehicle conditions are specified in Table A and in the Safety Emissions Section PART II Information Concerning United States and Canada Safety Standards The vehicle alterer is responsible for certifying the altered vehicle pursuant to Title 49 of the Code of Federal Regulations Sections 567 7 and 568 8 in the United States or pursuant to Section 9 of the Canadian Motor Vehicles Safety Regulations in Canada As outlined in these requirements the vehicle alterer must ascertain which F CMVSS are affected by the alteration and subsequently provide certification that the altered vehicle conforms to all affected safety standards In the information that follows Ford has endeavored to provide sufficient instructions and guidelines to the vehicle alterer for certifying that the vehicle conforms to all F CMVSS affected by the vehicle alteration Information pertaining to Certification Labeling Requirements for the altered vehicle is outlined at the end of Part Il Federal and Canadian Motor Standards Compliance Conformity to the following FMVSS FMVSS and Canadian Motor Vehicle Safety Standards CMVSS are affected by the removal of the pickup box and rear bumper a
7. the frame at the rear of the cab b Maximum SUB center of gravity CG shown in this table is only allowable if F CMVSS 105 criteria are satisfied per calculation in the Safety Emission section of this book c Weight shown is maximum allowable for safety certification for vehicles with a GVWR less than or equal to 10 000 Ibs www fleet ford com truckbbas Body Builders Layout Book 2013 MODEL YEAR TABLE B SUPER DUTY F SERIES TIRE AND WHEEL WEIGHTS Wheel Size Wheel only Weight Ib 17x7 5 Steel Wheel F250 350 SRW 37 8 17x7 5 Aluminum Wheel F250 350 SRW 27 2 17x6 5 Steel Wheel F350 DRW 39 2 17x6 5 Aluminum Wheel F350 DRW 24 8 18x8 0 Steel Wheel F250 350 SRW 43 4 18x8 0 5 spoke Aluminum Wheel F250 350 SRW 32 3 18x8 0 6 spoke Aluminum Wheel F250 350 SRW 32 5 19 5 x 6 0 Steel Wheel F450 550 DRW 51 1 19 5 x 6 0 Aluminum Wheel F450 550 DRW 34 6 19 5 x 6 0 RW Steel Wheel DRW 52 0 19 5 x 6 75 K Steel Wheel DRW 42 5 Tire Size Tire Weight Ib LT245 75R17 45 9 LT265 70R17 50 8 LT275 65R18 51 4 LT275 70R18 60 3 225 70R19 5 62 0 LT275 65R20 60 5 Typical tire weight F53 F59 Basic Stripped Chassis
8. 496 No axle ratio tire size or tire type changes are made that would increase the drivetrain ratio by more than 5 For additional information concerning noise control laws and regulations issued by the Federal U S Government as well as some states and municipalities see Vehicle Noise Regulations in the Safety Emissions section NOTE The maximum unloaded vehicle weight specified in Table A for California is the curb weight the basic curb weight plus the weight of options of a greater than 33 installation rate 2013 MODEL YEAR NOTE If the weight in pounds of the altered vehicle exceeds the maximum unloaded vehicle weight specified in Table A corresponding to the particular pickup truck model the vehicle alterer is required to certify the vehicle to the following Standards in addition to any other F CMVSS to which conformity is affected by the vehicle s alteration F CMVSS No 105 Hydraulic and Electric Brake Systems F CMVSS No 126 Electronic Stability Control FICMVSS No 204 Steering Control Rearward Displacement if the unloaded vehicle weight is 5500 Ib or less F CMVSS No 208 Occupant Crash Protection if the unloaded vehicle weight is 5500 Ib or less F CMVSS No 212 Windshield Mounting F CMVSS No 219 Windshield Zone Intrusion F CMVSS No 301 Fuel System Integrity Altered vehicles which do not satisfy these conditions may not be sold offered
9. ERATIONS DESIGN RECOMMENDATIONS Cont d 5 For a chassis certified pickup truck having a GVWR of up to 14 000 Ib other than those for sale registration or use in California the alterer does not add more than 500 Ib to the maximum unloaded vehicle weight specified in Table A corresponding to the particular pickup model a IMPORTANT Some of the preceding conditions are based in part on statements made by C N Freed of the Environmental Protection Agency EPA in a letter of July 13 1979 to M H McBride legal counsel of the Recreation Vehicle Industry Association That letter explained EPA s policy concerning alterers of complete 1980 and later model year light duty trucks in the context of EPA s Advisory Circular No 64 a March 7 1977 publication that provides guidance on the need for separate certification of vehicles modified after original manufacture but prior to sale and delivery to the ultimate purchaser The maximum second unit body weights provided in Table A are calculated in accordance with the definition of maximum vehicle weight provided in the July 13 1979 letter The letter provides that alterers of complete light duty trucks need not re certify such vehicles for emission control purposes if 1 the altered vehicles conform in all material respects to the design specifications in the original manufacturer s application for certification and 2 the weight of the altered vehicle including the we
10. Such modifications could void the authority to operate the device FREQUENCY NOTES 1 For vehicles with a GVWR of 10 000 Ib or less and an unloaded vehicle weight of 5500 Ib or less 2 Applicable to vehicles with a GVWR of 10 000 Ib or less 3 F CMVSS 105 is applicable to vehicles with GVWR over 3500 Kg 7716 Ib Cont d next page T PICKUP BOX REMOVAL PART III Cont d 2 CANADIAN RADIO FREQUENCY INTERFERENCE RFI INFORMATION All vehicles powered by spark ignition engines e g gasoline natural gas or propane engines and manufactured in Canada or for sale or use in Canada are subject to the Canadian Regulations for the Control of Interference to Radio Reception per Interference Causing Equipment Standard ICES 002 and applicable test method according to CAN CSA C108 4 06 Limits and Methods of Measurement Violation of these regulations is punishable by fine or imprisonment Ford built vehicles were designed and manufactured to be capable of meeting the regulatory requirements or such modifications thereof as may have been authorized by the Department of Communications However because Ford Motor Company has no control over how an altered vehicle is completed by subsequent stage manufacturers Ford Motor Company does not represent that the completed vehicle incorporating the Ford built components will comply with applicable requirements The following information is supplied t
11. be equipped with the convex mirror on the passenger s side when the SUB blocks the view through the inside mirror If the SUB is wider than the pickup box both the driver s side and passenger s side mirrors may have to be replaced with mirrors providing a wider view to the rear Trailer Tow Mirrors on Super Duty F Series These mirrors will continue to meet Standard No 111 provided the mirrors the driver s seat and the cab are not altered www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS DESIGN RECOMMENDATIONS Cont d If the front bumper and bumper mounting system are removed temporarily the front bumper and bumper mounting system must be reinstalled in accordance with the instructions provided in the Ford Truck Service Manual If the front bumper and bumper mounting system are replaced the replacement front bumper and bumper mounting system must not result in steering column rearward displacement of more than 5 inches as defined in F CMVSS No 204 1 any increases in injury criteria as defined in F CMVSS No 208 any additional loss of windshield retention as defined in F CMVSS No 212 2 any penetration of the inner surface of the windshield or intrusion into the protected zone as defined in F CMVSS No 219 2 or loss of fuel system integrity as defined in F CMVSS No 30102 when the vehicle is impacted in any manner specified by applicable provisions of those standa
12. e to employ other limits or conditions than those provided herein NOTE It is the responsibility of the vehicle alterer to assure compliance and certification of the altered vehicle to the applicable safety and or emissions including Noise and RFI requirements Specific questions concerning compliance and or certification to safety standards and emissions and fuel economy regulations should be directed to the vehicle alterer s legal counsel or the United States National Highway Traffic Safety Administration FMVSS and Federal Fuel Economy Standards and requirements the Canada Ministry of Transport CMVSS emissions and noise regulations the Canada Department of Communications Canadian RFI regulations the www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS INDEX United States Environmental Protection Agency EPA United States emission requirements or the California Air Resources Board California emissions and fuel vapor recovery requirements and the vehicle noise emission control authorities if any in the state and locality in which the vehicle is sold If you have technical product related questions concerning some aspect of the vehicle alteration a representative of Ford Motor Company will be happy to talk with you Please contact your regional sales office or email the Ford Truck Body Builders Advisory Service via the web at www fleet ford com truckbbas under
13. e vehicle owner s guide and the applicable Ford Motor Company RV and Trailer Towing Guide Any questions should be directed to the Body Builder Advisory Service at www fleet ford com truckbbas under the Contact Us tab Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS DESIGN RECOMMENDATIONS Cont d 2013 MODEL YEAR FRONT OF Frame mounted bracket long version shown FIGURE A LH FRAME MOUNTED BRACKET REQUIRED ON NON SERVICE APPLICATION SECOND UNIT BODY SUB INSTALLATIONS E G STAKE PLATFORM ETC PICKUP BOX DELETE ONLY Cont d next page 4 PICKUP BOX REMOVAL PART Il Cont d Example A vehicle alterer wants to remove the pickup box and rear step bumper from a Super Duty F 250 Regular Cab 4x4 137 inch WB model with a 6 2L engine automatic transmission and air conditioning having a curb weight of 6340 Ib and install a 600 pound Second Unit Body SUB The SUB weight must not exceed the SUB WEIGHT LIMIT calculated below SUB WEIGHT LIMIT Maximum Complete Unloaded Vehicle Weight UVW Table A minus the unloaded vehicle weight as delivered OEM curb weight plus pickup box weight removed plus weight of removed options 7819 6340 380 74 1933 Ib The 600 Ib SUB is less than 1933 Ib and accordingly may appropriately be installed as planned If the SUB is heavier than the maximum limit the vehicle alterer must eit
14. ed by restrictions GVWR less than or equal to 4536 kg 10 000 Ib maximum frontal area 3 76 m2 40 5 ft2 GVWR greater than 4536 kg 10 000 Ib maximum frontal area 4 74 m2 51 0 ft2 DRW maximum completed curb weight 4763 kg 10 500 Ib NOTE Frontal area requirement includes the cab and second unit body The completed vehicle must meet Maximum UVW weight for a GVWR of 4536 kg 10 000 Ib or less 3 The Super Duty F Series fuel filler kit that is supplied with the vehicles ordered with pickup box delete option number 66D or available through Ford dealers Installation must be as shown in the Super Duty F Series section 4 The alterer does not exceed the limitations listed in Safety Emissions pages under Curb Weight and Frontal Area Restrictions NOTE If the weight of the altered vehicle exceeds the maximum unloaded vehicle weight specified in Table A corresponding to the particular pickup truck model and engine combination the vehicle alterer is required to certify the vehicle to F CMVSS 105 Brakes F CMVSS No 204 0 Steering Control Rearward Displacement F CMVSS No 212 2 Windshield Mounting F CMVSS No 214 2 Side Impact Protection and F CMVSS 219 2 Windshield Zone Intrusion and F CMVSS No 301 2 Fuel System Integrity in addition to compliance with any other F CMVSS affected by the vehicle s alteration www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALT
15. ence with a service body upfit it may be removed and still maintain Standard 301 compliance All other SUB upfits including platform amp stake bodies require this bracket remain attached as installed by Ford Motor Company Except for a service body upfit with a rear bumper there must not be any components that tie a second unit body SUB to the frame rearward of rear spring s rear hanger shackle brackets Note that components for lateral support may be bolted or welded to either the chassis only or the second unit body only A service body upfit with a rear bumper attached via a bracket that ties the second unit body SUB to the frame must not exceed 6 35mm 0 25 in gauge thickness www fleet ford com truckbbas Additional Requirements for Platform Stake Body Upfits For platform stake body upfits only second unit body SUB longitudinal rail supports must not exceed 6 35mm 0 25 in gauge thickness To obtain pass thru compliance to Standard 301 for a platform stake body upfit if your vehicle is not equipped from the factory with a 16K rated frame mounted trailer hitch receiver i e equipped with a 12 5K rated hitch the hitch receiver must be removed and replaced with a 16K hitch receiver replaced with a 16K trailer hitch receiver Ford Engineering Part Number BC34 19D521 B Ford Service Part Number BC3Z 17D826 B The trailer tow capability of the vehicles remain unchanged as specified in th
16. es should be directed to body builders legal counsel the Environmental Protection Agency or the California Air Resources Board 2013 MODEL YEAR A Exhaust and Requirements All complete and some incomplete heavy duty vehicles up to 14 000 lbs GVWR are emission certified to the chassis certification provisions of 40 CFR Part 86 Subpart S and the requirements amp restrictions of Subpart S apply All heavy duty engines in some incomplete vehicles having a GVWR of 9900 to 14 000 Ib GVWR and all vehicles over 14 000 Ib GVWR for the United States and Canada have been certified to the applicable U S Federal or Canadian exhaust or California exhaust and evaporative emissions requirements for heavy duty engines Super Duty F Series pickup truck models listed in Table A if altered by removal of the pickup box including items attached to the pickup box rear bumper if so equipped and installation of a second unit body may not require re certification to applicable Federal California or Canadian emissions requirements if the following conditions are satisfied 1 None of the emission control hardware furnished with the pickup truck is deleted modified or rendered inoperable A listing of such hardware is provided under Emission Control Modifications in the Safety Emission section of this book 2 Any vehicle emission frontal area limitations are not exceeded as noted on the underhood Vehicle Emission
17. ess These lamps and reflectors are available from Ford in the form of rear lamp assemblies and are the same as those installed on Ford chassis cab models Cont d next page 3 PICKUP BOX REMOVAL F250 350 PICKUPS WITH GVWR RATINGS OF 10 000 LBS OR LESS PICKUP BOX REMOVAL REQUIREMENTS FOR F CMVSS 301 Ref BBAS Quality Bulletin Q183 Vehicles will comply if guidelines and recommendations are followed as specified in the Truck Body Builders Layout Book Information is also available in the applicable Super Duty F Series ncomplete Vehicle Manual Standard 301 pass thru compliance guidelines relative to the fuel system chassis and trailer hitch receiver The IVM is available at www fleet ford com truckbbas under the Publications tab The revised additional requirements are summarized as follows General Upfit Requirements Except for a service body upfit with a rear bumper there must not be any components that tie a second unit body SUB to the frame rearward of rear spring s rear hanger shackle brackets Note that components for lateral support may be bolted or welded to either the chassis only or the second unit body only Pickup Box Delete vehicles Sales Code 66D incorporate an outboard LH frame mounted bracket Ref Figure A required as part of pickup truck Standard 301 compliance Ford recommends that this bracket not be removed for SUB installation however if there is an interfer
18. formity to Federal Motor Vehicle Safety Standard FMVSS and Canadian Motor Vehicle Safety Standard CMVSS No 212 and 219 for vehicles having a gross vehicle weight rating as defined in 49 CFR Part 571 3 no greater than 4536 kg 10 000 Ib is established for representative vehicles at a vehicle weight provided by Sections S6 1 b and S7 7 b of FMVSS No 212 and 2189 respectively and provided by Sections 5 1 and 8 of CMVSS No 212 and 219 respectively The second unit body installed shall be mounted securely and so designed that when the altered vehicle is impacted in any manner specified by applicable provisions of F CMVSS No 212 2 and 21902 second unit body deformation or movement relative to the frame does not result in any separation or loss of body attachment to the frame The second unit body installed and the required fuel system components identified below shall be located and mounted as follows 2013 MODEL YEAR The second unit body shall be mounted securely and is so designed that when the altered vehicle is tested in any manner specified by applicable provisions of F CMVSS No 301 2 a Second unit body components shall not contact any fuel system component other than at the points where the fuel system is permanently attached to the second unit body and b Second unit body deformation or movement relative to the frame shall not cause any fuel system component to be penetrated disc
19. her select a lighter weight SUB reduce the OEM accessory weights for the vehicle or both 1 OEM Curb Weight includes Base Vehicle Weight with full fuel engine and transmission weight and all OEM accessory weights ordered or installed Refer to the appropriate Truck Source Book for weight data or email the Ford Truck Body Builders Advisory Service via the web at www fleet ford com truckbbas under the Contact Us tab 2 Options removed include step bumpers or similar OEM options permanently removed from the vehicle 3 The center of gravity height and overall height of the second unit body installed by the alterer must not exceed the values specified in Table A corresponding to the particular pickup model Center of gravity height and overall height of the second unit body are measured from the top surface of the frame at the rear of the cab 4 The altered vehicle s Unloaded Vehicle Weight see Definitions section must not exceed the values designated in Table A corresponding to the pickup trucks model and non California engine transmission combination www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS DESIGN RECOMMENDATIONS Cont d 5 These instructions must be followed in the vehicle alteration The following components as installed by Ford Motor Company are not to be removed relocated altered nor modified in any way Steering column steering shaft steeri
20. hout benefit of the Ford provided heat shields must be capable of withstanding 371 C 700 F and 482 C 900 F in close proximity to the catalyst during normal operating conditions Additionally any under chassis mounted component within 4 inches of the exhaust system must be compatible with these temperatures IMPORTANT INFORMATION CONCERNING ALTERATION OF LIGHT DUTY TRUCKS AND CHASSIS CERTIFIED MEDIUM DUTY VEHICLES WITH A GVWR OF UP TO 14 000 LB FOR SALE REGISTRATION OR USE IN CALIFORNIA Pickup trucks listed in Table A and manufactured by Ford Motor Company for sale registration or use in California can be altered by removal of the pickup box including items attached to the pickup box and rear bumper if so equipped and installation of a second unit body if all of the following conditions are satisfied Conditions noted on previous pages under Section A entitled Exhaust and Evaporative Emission Requirements numbered 1 2 3 and 4 and those under Section C entitled California Fuel Vapor Recovery as they apply to light duty trucks and medium duty vehicles The vehicle alterer does not increase the vehicle s unloaded vehicle weight by more than 1096 over the maximum curb weight unloaded vehicle weight specified in Table A corresponding to the particular pickup model does not increase the frontal area by more than 10 or does not provide a combination increase of weight plus frontal area of more than 1
21. ight of fuel at nominal tank capacity is no more than 500 Ib above the maximum vehicle weight The letter further states that no frontal area restrictions will apply to alterers who comply with conditions a and b above Alterers who do not comply with these conditions will be considered manufacturers under the Clean Air Act and will be required to assure that the altered vehicles are certified Questions concerning EPA policies with respect to alterers of completed vehicles should be directed to legal counsel or the Environmental Protection Agency b NOTE For a pickup truck having a GVWR of 10 000 Ibs or less If the weight of the altered vehicle exceeds the maximum unloaded vehicle weight specified in Table A corresponding to the particular pickup truck model and non California engine transmission combination the vehicle alterer is required to certify the vehicle to F CMVSS No 105 Brakes F CMVSS No 204 Steering Control Rearward Displacement if the unloaded vehicle weight is 5500 Ib or less F CMVSS No 208 Occupant Crash Protection if the GVWR is 8500 Ib or less and the unloaded vehicle weight is 5500 Ib or less F CMVSS No 212 Windshield Mounting F CMVSS No 214 Side Impact Protection F CMVSS No 219 Windshield Zone Intrusion and F CMVSS No 301 Fuel System Integrity in addition to compliance with any other F CMVSS affected by the vehicle s alteration See next page for important information concer
22. nd installation of an aftermarket second unit body Vehicle Safety F CMVSS No 105 1 F CMVSS No 108 F CMVSS No 111 F CMVSS No 1262 F CMVSS No 204 3 Hydraulic Brakes Lighting Equipment Rear view Mirrors Electronic Stability Control Steering Control Rearward Displacement F CMVSS No 208 F CMVSS No 212 4 F CMVSS No 214 4 F CMVSS No 219 4 F CMVSS No 301 4 Occupant Crash Protection Windshield Mounting Side Impact Protection Windshield Zone Intrusion Fuel System Integrity Ford Motor Company represents that in the case of a Super Duty F Series pickup truck listed in Table A this vehicle as altered will conform to the requirements of the previously listed safety standards provided the vehicle is altered only by the removal of the pickup box including optional equipment attached to the pickup box and rear bumper if so equipped and the installation of an aftermarket Second Unit Body SUB in accordance with the following conditions 1 The following lighting components must be designed and installed on the altered vehicle in accordance with the requirements of F CMVSS No 108 Lamps Reflective Devices and Associated Equipment Tail Lamps Stop Lamps License Plate Lamps Back Up Lamps Rear Turn Signal Lamps Rear Side Marker Lamps Rear Side Reflex Reflectors Reflectors Center High Mounted Stop Lamp if second unit body blocks view of the
23. ng wheel and related structural components and attachment hardware Windshield and windshield mounting system Cab and front end structural components including the roof pillars cowl cowl reinforcements hood doors fenders hood restrictors and apron reinforcements and frame and frame reinforcements Radio antenna Doors and hood mounting hinging and latching systems Hood and fender ornamentation Fuel tank and attachment hardware including sending unit and vapor valve fuel tank shield and in tank electric fuel pump for gasoline engine only Outboard LH frame mounted bracket Ref Figure A required as part of pickup truck Standard 301 compliance Ford recommends that this bracket not be removed for SUB installation however if there is an interference with a service body upfit it may be removed and still maintain Standard 301 compliance All other SUB upfits including platform amp stake bodies require this bracket remain attached as installed by Ford Motor Company Fuel lines routing and attachments excluding fuel filler cap filler pipe filler hose s and filler System attachment hardware which must be removed and replaced Vapor line s and carbon canister s Fuel pump Fuel filter and attachment Air cleaner assembly Safety belts Front seat head restraints Electrical grounds on all components must be retained The Powertrain Control Module PCM Catalyst and Exhaust S
24. ning alteration of light duty trucks and chassis certified medium duty vehicles rated at 14 000 Ib GVWR or less for sale registration or use in California B High Altitude Emissions Vehicles sold for principal use in high altitude areas must comply with the High Altitude Regulations United States Environmental Protection Agency regulations contain unique emission certification requirements for trucks that will be sold or delivered to customers for principal use above 4 000 feet 1219 meters Certain new vehicles cannot be sold to customers who intend to use them principally at high altitudes TO AVOID ANY QUESTION OF CERTIFICATION COVERAGE ORDERS SHOULD SPECIFY WHETHER A HIGH ALTITUDE EMISSION SYSTEM OR A NON HIGH ALTITUDE EMISSION SYSTEM IS REQUIRED C California Fuel Vapor Recovery California regulations require that vehicle fuel systems be designed to accommodate a new vapor recovery fueling nozzle including unobstructed access to the fill pipe Fuel filler pipes installed per Super Duty F Series section of this book will comply with the Specifications for Fill Pipes and Openings of Motor Vehicle Fuel Tanks referenced in Title 13 California Administrative Code providing no part of the second unit body as installed intrudes within the access zone defined in CARB regulation 13 CCR 2235 Fuel filler pipes installed using the alternate bracket shown on the figures in Super Duty F Series section of this book will comply
25. o subsequent stage manufacturers to help them avoid increasing the RFI emissions of this vehicle in the course of completing it For any altered vehicle additional measures may be needed to adequately suppress RFI emissions Affected components could include spark plugs electronic engine control module ground straps ignition component shields accessory drive belts and instrument voltage regulator suppressor assembly More specifically All components required to suppress RFI emissions which are removed during service repair or completion of the vehicle must be re installed in the manner in which they were installed by Ford Shields on ignition coil must remain installed Replacement of spark plugs ignition wires and ignition coil must be equivalent in their RFI suppression properties to original equipment Electrical grounds on all components must be retained Metallic components installed on the body or chassis must be grounded to the chassis Electrical circuits added to the vehicle must not be installed near the high voltage ignition components www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS DESIGN RECOMMENDATIONS Cont d Only static conductive accessory drive belts should be used Fan water pump power steering and other belts should be of the OEM type or equivalent that will not build up a static electrical charge Engine component wiring must n
26. onnected or otherwise damaged The rear end of the second unit body excluding the rear bumper installed shall not extend beyond overhang the rear edge of the vehicle frame or frame extension Any extension of the vehicle frame must be constructed and attached So as to perform as a continuation of the vehicle frame when the altered vehicle is tested in any manner specified by applicable provisions of F CMVSS No 30102 See the Design Recommendations Second Unit Body SUB attachment section of this book for additional information The fuel filler cap filler pipe filler hose s and filler system attachment hardware for vehicles with diesel engines and for vehicles with gas engines shall be installed as shown in the Super Duty F Series section and shall be securely retained to remain intact when the vehicle is tested in any manner specified by applicable provisions of F CMVSS No 301 2 NOTES 1 For vehicles with a GVWR of 4536 kg 10 000 Ib or less and an unloaded vehicle weight of 2495 kg 5500 Ib or less 2 Applicable to vehicles with a GVWR of 4536 kg 10 000 Ib or less 3 Standard 105 applies to vehicles with a GVWR over 3500 kg 7716 Ib Cont d next page 5 PICKUP BOX REMOVAL PART II Cont d The front end of the second unit body installed shall be located at least three inches rearward of the rearmost point of the cab on Super Duty F Series The vehicle as produced b
27. ot be rerouted in any manner The Powertrain Control Module PCM must not be relocated from the position as installed by Ford Motor Company E Noise Canadian Motor Vehicle Safety Standard CMVSS Section 1106 Noise Emissions prescribes maximum permissible exterior sound levels depending on the vehicle type and GVWR when tested in accordance with certain test methods or recommended practices CMVSS 1106 also prescribes a maximum interior sound level for trucks and buses with a GVWR greater than 4 536 kg 10 000 Ibs WARNING VEHICLE OPERATING TEMPERATURES Some trucks of Ford Motor Company may exhibit high engine compartment and exhaust system temperatures in some operating modes Components including exhaust heat shielding systems have been installed on some vehicles in our assembly plants in an effort to provide protection against such temperatures Subsequent aftermarket installers manufacturers are responsible for providing thermal protection e g underbody heat shields for any structure equipment added to the vehicle and should not remove any components exhaust heat shielding installed on the vehicles by Ford Also the added structure equipment should not restrict air circulation in the engine compartment or underbody See applicable sections under Ambulance Builders Guidelines in the Design Recommendations section Any interior floor underlayment or insulation in the near vicinity of the exhaust system wit
28. rds NOTE The second unit body added by the vehicle alterer may have to conform to other safety standards as well For example any glazing used in the second unit body must conform to F CMVSS No 205 Glazing Materials Additionally if the second unit body is equipped with any passenger seating positions the following safety standards may be applicable as well F CMVSS No 206 Door Locks and Retention F CMVSS No 207 Seating Systems F CMVSS No 208 Occupant Crash Protection F CMVSS No 209 Seat Belt Assemblies F CMVSS No 210 Seat Belt Anchorages F CMVSS No 214 2 Side Impact Protection F CMVSS No 302 Flammability of Interior Materials With respect to the second unit body installed and the above mentioned safety standards it is the responsibility of the vehicle alterer to assure conformity with all applicable requirements It is the responsibility of the vehicle alterer to determine which other safety standards if any their vehicles must comply with NOTE See statements for F CMVSS No 105 Hydraulic Brake implications of modifications alterations to completed vehicles including pickup box removal vehicles in the Safety Emission section Certification Labeling Requirements For altered vehicles in the United States the vehicle alterer is required to affix an additional label containing the information shown in the Safety Emissions section NOTE The safety standard certification label which is
29. s Compliance Information VECI label Some heavy duty incomplete vehicles are certified using chassis certification protocol and will require vehicle weight and frontal area restrictions to retain emission certification If your vehicle is affected the frontal area and unloaded vehicle weight information will be found on the VECI label which is located in the engine compartment Incomplete vehicles with engines certified using heavy duty engine protocol are not limited by weight and frontal area restrictions for exhaust emissions It is important that the final stage manufacturer observe vehicle restrictions from vehicle safety requirements etc which are located elsewhere in this manual Additional emissions certification information is contained in the Ford Truck Body Builders Layout Book for the model year and type of this incomplete vehicle Evaporative Emission NOTES 1 For vehicles with a GVWR of 10 000 Ib or less and an unloaded vehicle weight of 5500 Ib or less 2 Applicable to vehicles with a GVWR of 10 000 Ib or less Cont d next page 6 PICKUP BOX REMOVAL PART III Cont d The following Frontal Area and Weight Restrictions apply to the completed vehicle 6 2L Engine NOTE Export vehicles use U S emissions Maximum frontal area 6 69 m2 72 0 ft2 SRW DRW DRW maximum completed curb weight 4809 kg 10 603 Ib 6 7L Engine NOTE Euro Il Euro Ill emissions not affect
30. with the above California vapor recovery regulations provided the second unit body installed does not interfere with the access zone 2013 MODEL YEAR D Radio Frequency Interference RFI 1 UNITED STATES RADIO INTERFERENCE RFI INFORMATION Devices that emit radio frequency RF energy such as AM FM radios and radio controlled theft alarms marketed for sale or use in the United States are subject to the rules and regulations of the Federal Communications Commission FCC 47 C F R Parts 2 and 15 These rules specify the following conditions of operation This device complies with Part 15 of the FCC rules Operation is subject to the following two conditions 1 This device may not cause interference and 2 The device must accept any interference received including interference that may cause undesired operation In addition the FCC s rules may require the device to be tested and found to comply with various RF interference emissions limits before it may be marketed The FCC established different limits according to the particular use and installation of RF devices In some cases a grant of equipment authorization from the FCC also must be obtained before and RD device may be marketed To ensure continued compliance with the FCC s requirements the owner user custom manufacturer or service technician must not modify or change the RF device in a manner not expressly approved by Ford Motor Company
31. y Ford Motor Company meets the Center High Mounted Stop Lamp CHMSL requirements of Standard 108 Lighting Compliance to these criteria may be affected by the installation of a Second Unit Body SUB if the SUB blocks the view of the CHMSL mounted on the back of the cab When this happens the subsequent manufacturer must install a CHMSL on the SUB that meets FMVSS 108 An electrical feed for installation of a CHMSL on the SUB is provided and is located inside the rearmost crossmember near the end of the left frame rail on the Super Duty F Series models The vehicle as produced by Ford meets F CMVSS No 111 Compliance to F CMVSS No 111 may be affected however by removal of the pickup box and installation of a Second Unit Body SUB even though the mirror system has not been altered A discussion of compliance with respect to each mirror type follows Sail Mounted Type Outside Mirror on Super Duty F Series Pickup Provided the mirrors driver s seat and cab are not altered the mirror system will continue to meet Standard No 111 if the overall width of the Second Unit Body SUB is no wider than the pickup box and if the view of the roadway behind the vehicle through the inside mirror is not totally blocked off If the SUB blocks the view through the inside mirror a flat glass mirror is required on the passenger s side in place of the convex mirror on vehicles to be sold in the United States Vehicles for sale in Canada may
32. ystem Trailer hitch receiver CGv must adhere to C FMVSS Standard 126 Electronic Stability Control System limitations Any alteration or modification made to the vehicle as manufactured by Ford Motor Company and any components or structure installed by the vehicle alterer must not result in steering column rearward displacement of more than 5 inches as defined in FICMVSS No 204 0 no modification to the Hydraulic Brake System that would affect compliance to F CMVSS No 105 an increase in injury potential for front outboard seating positions as defined in F CMVSS No 208 any additional loss of windshield retention as defined in F CMVSS No 2122 any change in the performance requirements of F CMVSS 21405 any penetration of the inner surface of the windshield or intrusion into the protected zone as defined in F CMVSS No 2192 or loss of fuel system integrity as defined in F CMVSS No 30102 when the vehicle is tested in any manner specified by applicable provisions of F CMVSS No 105 9 204 0 208 21200 21402 219 2 and 30102 respectively NOTE Federal Motor Vehicle Safety Standard FMVSS and Canadian Motor Vehicle Safety Standard CMVSS No 204 are not applicable to a vehicle with an unloaded vehicle weight greater than 2495 kg 5500 Ib F CMVSS No 2068 injury criteria are applicable only to vehicles with a GVWR of 3856 kg 8500 Ib or less and an unloaded vehicle weight of 2495 kg 5500 Ib or less Con
Download Pdf Manuals
Related Search