Ford Expedition Modifiers Manual
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Ford Expedition Modifiers Manual

Special service vehicle (ssv)
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EXPEDITION
EXPEDITION EL
2010
2010

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Summary of Contents for Ford Expedition

  • Page 1 2010 2010 EXPEDITION EXPEDITION EL...

  • Page 2: Introduction

    Ford Mo tor Company.
  • Page 3 SECTION 0 Introduction Contents Introduction..................0-1 2010 Expedition SSV Modifiers Guide, 07/2009...
  • Page 4 Introduction Ford Motor Company has assembled this Expedition Special Service Vehicle (SSV) Modifiers Guide to assist vehicle modifiers in producing safe and quality products. Ford believes that safety and quality come first. This book is divided into topics pertinent to modifiers of vehicles. Reference is made to the current...

  • Page 5: Table Of Contents

    SECTION 1 General Information Contents Section 1: General Information ............1-1 Important Safety Notice..............1-1 Warnings, Notices and Notes ...........1-1 Making Safety Devices and Elements Inoperative....1-2 Special Service Vehicle (SSV) Definition........1-3 Identification Codes ..............1-5 Good Practices ................1-9 Process and Quality Assurance Systems ........1-9 Quality Assurance ..............1-9 Minimum and Maximum Screw Sizes ........1-9 New Vehicle Storage..............1-9...

  • Page 6: Section 1: General Information

    Note: The descriptions and specifications contained in this guide were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring obligation.

  • Page 7: Making Safety Devices And Elements Inoperative

    General Information Section 1: General Information The following list contains some general warnings that you should follow when you work on a vehicle. WARNING: • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires you to be under the vehicle. •...

  • Page 8: Special Service Vehicle (Ssv) Definition

    General Information Section 1: General Information Special Service Vehicle (SSV) Definition Special Service Vehicles (SSV) are offered to fill the special needs of police agencies that a standard patrol car can not. SSV Standard Package Deletes Item Floor console Floor mats Fog lamps Third-row seat Standard Equipment...

  • Page 9: Standard Equipment

    General Information Section 1: General Information Standard Equipment System Description Interior Second and third row coat hooks Second row map lights Manual A/C with auxiliary climate controls AM/FM single CD, 6-premium speakers (160-watts peak), driver adjusted speed compensated volume, partitioned audio, rear seat controls and MP3 capability Color-keyed assist handles Auxiliary audio input jack in instrument panel Cargo organizer (Expedition EL only)

  • Page 10: Identification Codes

    General Information Section 1: General Information Miscellaneous Options (See sales brochure for complete list of available options) Item Description Exterior Options Daytime running lamps (43D) Engine block heater (41H) Heated sideview mirrors (54H) Running boards (4x4 only) (186) Seat Options First row 40/60 split bench cloth with power adjustable driver’s seat (M) Second row 40/20/40 split bench cloth (N/A with 875 third row seat) (21F) Second and third row bench cloth (requires 574 rear aux A/C and heat)
  • Page 11 General Information Section 1: General Information Vehicle Certification (VC) Label Code Positions Position Description Exterior paint code Region code District Special Order (DSO) Wheelbase code Interior trim code Tape/paint pinstripe code Radio code Axle code Transmission code Spring code Powertrain calibration information 2010 Expedition SSV Modifiers Guide, 07/2009...
  • Page 12 General Information Section 1: General Information 1. Exterior Paint Color Code The first set of numbers/letters listed indicate the vehicle primary body color code. The second set of letters/numbers listed (if applicable) indicate a 2-tone or accent body color code. •...
  • Page 13 General Information Section 1: General Information 7. Radio Type • 1 — AM/FM stereo with in-dash, 6-disc CD changer and clock • F — AM/FM stereo CD player, navigation system and clock • S — Premium electric AM/FM stereo CD player •...

  • Page 14: Good Practices

    All systems and functions that were provided by Ford should be checked to make sure that they function correctly after the build process. The modifier’s Process and Quality Assurance Systems should also make sure that appropriate training is provided to the employees.
  • Page 15 1-10 General Information Section 1: General Information New Vehicle Storage — Body • Wash vehicle thoroughly to remove dirt, grease, oil, tar or mud from exterior surfaces and underside of front fender. • Periodically wash vehicles stored in exposed locations. •...

  • Page 16: Tire Pressure Monitoring System (Tpms) Principles Of Operation

    (IC) and illuminates the TPMS indicator solid. If there is a system malfunction, the TPMS indicator flashes for 70 seconds and then goes solid. This vehicle, as delivered by Ford Motor Company, conforms to Standard FMVSS138, Tire Pressure Monitoring Systems.

  • Page 17: Ambient Temperature Change And Tire Pressure

    General Information Section 1: General Information The TPMS, as delivered from the Ford Motor Company, complies with part 15 of the FCC rules and with RS-210 of Industry Canada. Operation is subject to the following 2 conditions: • This device may not cause harmful interference •...
  • Page 18 General Information 1-13 Section 1: General Information As the ambient temperature decreases by 6°C (10°F), tire pressure decreases 7 kPa (1 psi). Adjust the tire pressure by 7 kPa (1 psi) for each 6°C (10°F) ambient temperature drop as necessary to keep the tire at the specified vehicle certification (VC) label pressure. Refer to the following tables to adjust the tire pressure indoors for colder outside temperatures.
  • Page 19 SECTION 2 Electrical Contents Section 2: Electrical .................2-1 Electrical Basics ................2-1 Electrical Systems Management ..........2-2 Generator Output................2-2 Charging Margins .................2-2 Vehicle Component Electrical Loads........2-2 Typical Police Equipment ............2-3 PCM — Red Area ................2-4 Disabling Brake Lights..............2-4 Auxiliary Power Point (12V DC) ...........2-4 General Guidelines ...............2-4 Splices and Repairs ..............2-14 How To Change Option Content..........2-19...

  • Page 20: Expedition Ssv Modifiers Guide,

    Electrical Section 2: Electrical Electrical Basics Inside a vehicle, electricity is supplied through powered wires (commonly called ‘‘hot’’ wires), comparable to the pressurized supply pipes of a plumbing system. At various points along the wires are outlets in the form of lights, switches and receptacles. Turning on a light switch is somewhat like opening a faucet to let water run —...

  • Page 21: Electrical Systems Management

    Electrical Section 2: Electrical Electrical Systems Management Care must be given in deciding what equipment should be installed into a police vehicle given the power demands of the equipment and the power available from the vehicle. A power load strategy should be developed to minimize the risk of running out of power.

  • Page 22: Typical Police Equipment

    Electrical Section 2: Electrical Component Amps Base Miscellaneous Base Loads 16.5 Cooling Cooling Fan (electric fan clutch) Climate Control A/C Clutch A/C Fan-to-Face — High Speed 18.9 A/C Fan-to-Face — M/H Speed 13.4 Heater Fan-to-Foot — M/H Speed 12.5 Auxiliary Blower — M/H Speed Auxiliary Blower —...

  • Page 23: Pcm - Red Area

    Electrical Section 2: Electrical PCM — Red Area NOTICE: DO NOT make electrical connections to vehicle electrical systems not specifically designed for police equipment installations. Damage to the electrical system can occur. Do not install any components into the PCM or PCM harness. Connecting into this system may affect engine and transmission operation.
  • Page 24 Expedition Workshop Manual. • Adherence to the above guidelines is not to be construed as approval by Ford Motor Company of any specific revisions or additions to the vehicle’s original electrical system.
  • Page 25 • Cross-linked Polyethylene (XPLPE or SXL), rated at 135°C (275°F), is the required insulation for underhood/underbody applications (Ford Specification ESB-M1L123-A). • GXL can be used as an alternate wire (Ford Specification ESB-M7L85B) as long as the concentricity specifications are met. To provide a water-resistant seal in conjunction with crimp connectors, a Duraseal crimp connector is recommended since it is designed to account for outside wire diameter that is smaller than the present SXL wire.
  • Page 26 Electrical Section 2: Electrical • Determine the terminal type. Base your decision on wire gauge, current carrying capacity, connector type and insulation type. — Use non-detent low insertion force terminals whenever possible. — Do not use low insertion force female terminals in weather-resistant connectors. —...
  • Page 27 Electrical Section 2: Electrical • Use 135% of the fuse rating when sizing wiring to protect the circuit in the event of an overload. Fuses will last for 1 hour at 135% of their rating. — Total current draw is the sum of the base vehicle’s circuit current requirement (measured with an ammeter) and the anticipated add-on component current requirements.
  • Page 28 • Tape — Tape is the most basic means of protection. It contains the wires in a loose bundle and provides limited environmental protection. It does not protect against chafing and pinching. — Kendall Polyken Fiberglass Base Tape (Ford Specification ESB-M3G38-A) is used for engine compartment applications. This durable tape provides against cut-through and abrasion commonly found in underhood applications.
  • Page 29 2-10 Electrical Section 2: Electrical • Scroll — Similar to convolute, but without the ridges. Scroll is used where harness rigidity is required, especially for maintaining critical locator dimensions. Use scroll for short lengths only, as it is quite inflexible. Note: This is not meant to be an all-inclusive list of methods for physically protecting the wires.
  • Page 30 Electrical 2-11 Section 2: Electrical • Route wires to avoid metal edges, screws, trim fasteners and abrasive surfaces. When such routing is not possible, use protective devices (shields, caps) to protect the wires. Cover metal edges with a protective shield and fasten the wiring within 76 mm (3 in) on each side of the edge (see figure below).
  • Page 31 • The wire retainers and grommets installed by the assembly plant are usually designed to accommodate only the Ford-installed wires. Additional wiring or tubing should be retained by additional clips. When added wires or tubes are routed through sheet metal panels, new holes with correct wire protection and sealing must be used.
  • Page 32 Electrical 2-13 Section 2: Electrical For retainer screws, the following guidelines apply: • Avoid using fasteners that are too long for the application or are in an area which might damage vehicle components, including wiring, brake lines, fuel tank and lines, powertrain components, exhaust system and suspension.

  • Page 33: Splices And Repairs

    2-14 Electrical Section 2: Electrical Splices and Repairs For quality splicing and to reduce potential problems, the following guidelines are recommended: • Stagger the splices within a harness to reduce increased harness diameter. Splice only on straight areas as installed, not on bends. •...
  • Page 34 Electrical 2-15 Section 2: Electrical 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist the wires together. 5. Note: Use resin-core mildly-activated (RMA) solder. Do not use acid-core solder. Solder wires together. 6. Note: Wait for solder to cool before moving wires. Bend wire 1 back in a straight line.
  • Page 35 2-16 Electrical Section 2: Electrical 7. Note: Overlap tubing on both wires. Evenly position heat shrink tubing over wire repair. 8. Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing.
  • Page 36 E6FZ-14488-C Butt Connector Gauge: 10-12, Color: Yellow Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2) Heat shrinkable tubing is available in various diameters for different splice sizes and configurations. When shrunk, it forms a small, flexible hermetic seal. Other methods (tape, PVC mold) do not provide a hermetic seal and are not recommended. Splice balancing is critical with heat shrink insulation.
  • Page 37 2-18 Electrical Section 2: Electrical 4. Select the appropriate wire slice for the wires to be spliced from Rotunda Wire Splice Kit 164-R5903. 5. Note: Rotunda 164-R5901 Pro-Crimper supplied with the wire splice kit is the only tool that can be used with these splices. Identify the appropriate chamber on the Rotunda Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice.

  • Page 38: How To Change Option Content

    Electrical 2-19 Section 2: Electrical 8. Check for acceptable crimp. (1) Crimp should be centered on each end of the butt splice. (2) Wire insulation does not enter butt splice. (3) Wire is visible through inspection hole of splices. 9. Evenly position supplied heat shrink tubing over wire repair. 10.

  • Page 39: Rear Power Window Disable

    Available publications include Workshop Manuals, Wiring Diagrams, PC/ED Manuals and Owner’s Literature. In addition, a publications order form can be obtained by writing to: Ford Publications, c/o Helm Inc., P.O. Box 07150, Detroit, MI 48207. 2010 Expedition SSV Modifiers Guide, 07/2009...
  • Page 40 SECTION 3 Installation Considerations Contents Section 3: Installation Considerations..........3-1 Mobile Radio Installation Guidelines ..........3-1 General Information ..............3-1 Spotlight Installation Location............3-4 Push Bumpers ................3-5 Siren and Grille Lights..............3-6 Partition Installation Guidelines ............3-6 Safety Belt Retractor and Side Impact Sensor ......3-7 Console Design and Installation...........3-8 Restraints Control Module (RCM) ..........3-8 Air Bag Deployment Interference ..........3-8 Seat Bolts..................3-9...

  • Page 41: Section 3: Installation Considerations

    Expenses incurred to protect the vehicle systems from any adverse effect of any such installation are not the responsibility of Ford Motor Company.
  • Page 42 Avoid running power leads in parallel with vehicle wiring over long distances. Note: On some Ford vehicles, the rear window contains the entertainment radio antennas (AM and FM). Avoid using the rear window to mount mobile radio antennas in these vehicles.

  • Page 43: Additional Information

    Some vehicles use glass that contains a thin metallic coating for defrosting or to control solar gain; glass mount antennas may NOT function correctly when mounted on this type of glass. (Ford Privacy Glass contains such a coating.) Also, refer to the antenna manufacturer’s recommendations.

  • Page 44: Spotlight Installation Location

    Installation Considerations Section 3: Installation Considerations If any vehicle radio interaction problems exist after following these guidelines, contact the radio equipment manufacturer for additional assistance. Additional Sources of Information Radio Frequency Interference: How to Find It and Fix It ISBN: 0-87259-375-4, The American Radio Relay League, Inc.

  • Page 45: Push Bumpers

    (there are a number of different styles available), it is the opinion of Ford Motor Company that installation of some push bumpers could affect the timing of the air bag deployment. Use of a push bumper that mounts solely to the vehicle’s bumper should not have a significant effect upon air bag deployment.

  • Page 46: Siren And Grille Lights

    Installation Considerations Section 3: Installation Considerations Siren and Grille Lights The engine cooling system relies on correct airflow through the radiator to keep the engine at its correct operating temperature. When adding sirens and grille lights to a vehicle, make sure this airflow is not obstructed.

  • Page 47: Safety Belt Retractor And Side Impact Sensor

    Installation Considerations Section 3: Installation Considerations Safety Belt Retractor and Side Impact Sensor Item Description Side impact sensor Front safety belt retractor The front safety belt retractors are located in the base of the B-pillars. The pretensioner located in the buckle is referred to as the ‘‘safety belt buckle pretensioner’’. In the event of an air bag deployment, pretensioners provide improved occupant protection by rapidly removing slack from the safety belt.

  • Page 48: Console Design And Installation

    Installation Considerations Section 3: Installation Considerations WARNING: The front side impact sensors are located in the front doors. These are pressure sensors that measure the pressure change in the front door during an impact. Do not mount anything on or in the door. Do not cut any holes in the door sheet metal, trim or water seals.

  • Page 49: Seat Bolts

    Installation Considerations Section 3: Installation Considerations Driver/passenger air bags affect the way police equipment can be mounted in police vehicles. Any surfaces that could come into contact with an air bag during deployment must not damage the air bag or alter its deployment path. Sharp edges, corners or protrusions could damage the nylon air bag material and reduce the effectiveness of the air bag.
  • Page 50 3-10 Installation Considerations Section 3: Installation Considerations A reset event will set the interior lamps interrupt timer to 0. The reset events for the interior lamps interrupt timer are: turning on the interior lamps by using the dome lamp switch or opening any door (as detected by the door ajar switches).
  • Page 51 SECTION 4 Cargo Mounting Considerations Contents Section 4: Cargo Mounting Considerations ........4-1 Cargo Area Equipment Mounting Guide ........4-1 Safety Belt Retractor and Side Impact Sensor (if equipped).................4-1 Auxiliary Climate Control System ..........4-3 Cargo Loading ................4-4 Cargo Area Weight...............4-5 2010 Expedition SSV Modifiers Guide, 07/2009...

  • Page 52: Section 4: Cargo Mounting Considerations

    Cargo Mounting Considerations Section 4: Cargo Mounting Considerations Cargo Area Equipment Mounting Guide NOTICE: When installing equipment, it is important to consider the available clearance between the brake lines and the fastener or component. Any fasteners or static components should allow a minimum of 15 mm (0.60 in) clearance to the brake lines. Any dynamic components should allow for a minimum of 19 mm (0.75 in) clearance to the brake lines.
  • Page 53 Cargo Mounting Considerations Section 4: Cargo Mounting Considerations Item Description Side impact sensor Second row safety belt retractor Third row safety belt retractor The second row safety belt retractors are located in the middle of the C-pillars. The third row safety belt retractors are located in the middle of the D-pillars.

  • Page 54: Auxiliary Climate Control System

    Cargo Mounting Considerations Section 4: Cargo Mounting Considerations WARNING: The rear side impact sensors are located in the C-pillars. The installation of hardware must not interfere with the correct operation of the rear side impact sensors. Failure to follow these instructions may result in personal injury. Auxiliary Climate Control System Note: Expedition EL shown, Expedition similar.

  • Page 55: Cargo Loading

    Section 4: Cargo Mounting Considerations Cargo Loading WARNING: Ford recommends that police equipment be both secured and laterally aligned. Hard, stiff or sharp objects, especially when not secured or correctly located, pose a risk to the occupants. Aftermarket organizers that do not adequately deform in rear-impacts can themselves become injury-producing objects.

  • Page 56: Cargo Area Weight

    Cargo Mounting Considerations Section 4: Cargo Mounting Considerations • Low Risk Items — These items are soft in feel and pose a low risk of potential injury capability in collisions. Examples are: a soft camera case, biohazard kit in plastic boxes, gloves, safety rope, tow strap, traffic cones and sleeves, rain gear, riot gear (soft), emergency blankets, bullet-resistant vests, tie straps, cloth tape, garment bags, first responder kit, Res-Q-Flo masks (placed in garment bag), fuses (plastic container), briefcases, notebooks, spray bottles, helmets...
  • Page 57 SECTION 5 Reference Information Contents Section 5: Reference Information ............5-1 Engineering Drawings ..............5-1 Air Bag Deployment Interference ..........5-1 Fuel Lines — Short Wheelbase..........5-5 Fuel Lines — Long Wheelbase ..........5-6 Fuel Tank — Cut View, Short Wheelbase .......5-7 Fuel Tank — Cut View, Long Wheelbase........5-8 Fuel Tank —...

  • Page 58: Section 5: Reference Information

    Reference Information Section 5: Reference Information Engineering Drawings Air Bag Deployment Interference WARNING: Do not place objects or mount equipment in front of the air bag module cover or in front seat areas that may come in contact with a deploying air bag, dash, tunnel or console-mounted equipment should be placed within the specified zone.
  • Page 59 Reference Information Section 5: Reference Information Figure 1. (1) 250 mm (9.8 in) from center of air bag door (2) 325 mm (12.8 in) from center of air bag door (3) 650 mm (25.6 in) Figure 2. 2010 Expedition SSV Modifiers Guide, 07/2009...
  • Page 60 Reference Information Section 5: Reference Information (1) 500 mm (19.7 in) (2) 300 mm (11.8 in) (3) 200 mm (8 in) Figure 3. No objects should be placed between the air bags due to air bag variability. (1) 300 mm (11.8 in) (2) 500 mm (19.7 in) (3) 260 mm (10.25 in) (4) 175 mm (7 in)
  • Page 61 Reference Information Section 5: Reference Information Figure 4. The curtain airbag extends from the A-pillar to the D-pillar and from the roof rail to the beltline. • Do not mount equipment to the B-, C- and D-pillars above the beltline. •...

  • Page 62: Fuel Lines - Short Wheelbase

    Reference Information Section 5: Reference Information Fuel Lines — Short Wheelbase Item Description Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009...

  • Page 63: Fuel Lines - Long Wheelbase

    Reference Information Section 5: Reference Information Fuel Lines — Long Wheelbase Item Description Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009...

  • Page 64: Fuel Tank - Cut View, Short Wheelbase

    Reference Information Section 5: Reference Information Fuel Tank — Cut View, Short Wheelbase Item Description Evaporative emissions hose Fuel tank Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009...

  • Page 65: Fuel Tank - Cut View, Long Wheelbase

    Reference Information Section 5: Reference Information Fuel Tank — Cut View, Long Wheelbase Item Description Evaporative emissions hose Fuel tank Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009...

  • Page 66: Fuel Tank - Bottom View, Short Wheelbase

    Reference Information Section 5: Reference Information Fuel Tank — Bottom View, Short Wheelbase Item Description Fuel lines Fuel tank 2010 Expedition SSV Modifiers Guide, 07/2009...

  • Page 67: Fuel Tank - Bottom View, Long Wheelbase

    5-10 Reference Information Section 5: Reference Information Fuel Tank — Bottom View, Long Wheelbase 2010 Expedition SSV Modifiers Guide, 07/2009...

  • Page 68: Fuel Tank - Top View, Short Wheelbase

    Reference Information 5-11 Section 5: Reference Information Item Description Fuel lines Fuel tank Fuel Tank — Top View, Short Wheelbase 2010 Expedition SSV Modifiers Guide, 07/2009...

  • Page 69: Fuel Tank - Top View, Long Wheelbase

    5-12 Reference Information Section 5: Reference Information Fuel Tank — Top View, Long Wheelbase 2010 Expedition SSV Modifiers Guide, 07/2009...

  • Page 70: Fuel Pump Shut-Off Switch

    Reference Information 5-13 Section 5: Reference Information Fuel Pump Shut-Off Switch Brake Lines NOTICE: When installing equipment, it is important to consider the available clearance between the brake lines and the fastener or component. Any fasteners or static components should allow a minimum of 15 mm (0.60 in) clearance to the brake lines. Any dynamic components should allow for a minimum of 19 mm (0.75 in) clearance to the brake lines.

  • Page 71: Technical Specifications

    Description Master cylinder Brake booster Brake lines Brake control module Technical Specifications Item Specification Specification Make: Ford Model: Expedition Special Service Sales Code: — Vehicle (SSV) Engine Displacement Cubic Inches: 330 Liters: 5.4 Fuel System Sequential Port Fuel Injection Exhaust...
  • Page 72 Reference Information 5-15 Section 5: Reference Information Item Specification Specification Torque 365 lb-ft @ 3,750 rpm Battery 750 cca Compression Ratio 9.8:1 Transmission Model: 6R80 Type: 6-speed electronic automatic with lockup torque converter and overdrive. Axle Ratio 3.73:1 Gross vehicle weight rating (GVWR) 3,333 kg (7,350 lb) (Expedition) or 3,492 kg (7,700 lb) (Expedition EL) (4x2) GVWR (4x4)
  • Page 73 5-16 Reference Information Section 5: Reference Information Item Specification Specification Behind Third Row Seat (optional) 0.51 cu m (18 cu ft) (Expedition) or 1.21 cu m (42.6 cu ft) (Expedition EL) EPA Mileage Est. (mpg) City: 16/Highway: 22 Combined: 18 Mileage Est.

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