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Important Notice
MARCH 2002

Summary of Contents

  • Page 1

    Important Notice MARCH 2002...

  • Page 2: Index

    Occupational FORD TRUCK BODY BUILDER ADVISORY SERVICE was approved for printing, but accuracy Safety and Health Act (OSHA), and/or The Ford Truck Body Builder Advisory Service assistance may be cannot guaranteed. They state, provincial, and local laws and consulted regarding information contained in this manual.

  • Page 3: Table Of Contents

    Technical Specifications Important Notice/Reference Information INDEX/FEATURES Index ........FEATURES Metric/U.S.

  • Page 4

    click here TO RETURN TO INDEX METRIC/U.S. CUSTOMARY UNIT EQUIVALENTS Page 2 E-550 SUPER DUTY CUTAWAY Multiply: to get: Multiply: to get: Multiply: to get: Multiply: to get: LINEAR FUEL ECONOMY inches 25.4 = millimetres(mm) 0.03937 inches miles/gal 0.4251 kilometres/litre (km/l) 2.352 miles/gal inches...

  • Page 5

    click TO RETURN TO INDEX E-550 SUPER DUTY CUTAWAY here MODEL LINEUP Page 3 E-550 SUPER DUTY CUTAWAY BASE CURB WEIGHT* BASE CURB WEIGHT* SERIES SERIES WHEELBASE WHEELBASE GVWR GVWR STANDARD STANDARD ENGINES ENGINES MODEL MODEL FRONT REAR TOTAL CODE TRANSMISSION mm/inches pounds...

  • Page 6

    NOTES — THIS INFORMATION IS PROVIDED TO ASSIST IN THE MARK MARK INSTALLATION OF SEATS OTHER THAN FORD INSTALLED BB0056 SEATS AND TO HELP PRESERVE THE INTENDED PERFORMANCE OF THE SAFETY AND ERGONOMIC FEATURES OF THE 2002 E-SERIES. THE MID-TRACK H-POINT LOCATION MUST BE MAINTAINED IN ORDER TO COMPLY WITH FMVSS 208 AIRBAG REQUIREMENTS.

  • Page 7: Seat Restraint System, Seat Restraint System

    OCCUPANT PROTECTION ZONE AND OVERHEAD configuration and vehicle design make it likely that the 3. Do not modify or alter Ford furnished seating or 2. Additional lap and shoulder belt assemblies, CONSOLE position will be used by an occupant while the vehicle occupant restraint system.

  • Page 8

    click E-550 SUPER DUTY CUTAWAY here TO RETURN TO INDEX OCCUPANT PROTECTION SYSTEMS Page 6 E-550 SUPER DUTY CUTAWAY SEAT RESTRAINT SYSTEM XC2A–15602B82 F65B–15602B90 F65B–602B90 ADJ. ASY . COVER ASY . XC2A–15602B82 COVER ASY . ADJ. ASY . PANEL ASY . UPPER CUTAWAY &...

  • Page 9

    E-550 SUPER DUTY CUTAWAY click TO RETURN TO INDEX here OCCUPANT PROTECTION SYSTEMS Page 7 E-550 SUPER DUTY CUTAWAY SEAT RESTRAINT SYSTEM SEAT ASY . SEAT ASY . PIA BOLT TORQUE CLEARANCE T2007563 40.0 6.0 Nm ZONE [29.5 4 FT-LB] SEAT CLEARANCE F7UB–1561202–A...

  • Page 10: Air Bag Supplemental Restraint System, Air Bag Supplemental Restraint System

    THE EVENT OF A COLLISION. plate (visible through the windshield) of the vehicle, representations provided in the Incomplete Vehicle manufactured by Ford with a driver’s air bag, are the 5. Reconnect all negative battery cables and Manua l (IVM). Also, additional information is provided If electrical work is performed in the steering column words “AIR”...

  • Page 11

    E-550 SUPER DUTY CUTAWAY click TO RETURN TO INDEX here OCCUPANT PROTECTION SYSTEMS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM Page 9 E-550 SUPER DUTY CUTAWAY STEERING INSTRUMENT WHEEL PANEL HARNESS AIRBAG AIRBAG ELECTRONIC CRASH SENSOR MODULE READINESS INDICATOR AIRBAG USAGE CHART VEHICLE DRIVER PASSENGER Standard Front...

  • Page 12: E-550 Super Duty Cutaway 159.5i - 233.5i Wheelbase (drw)

    DIMENSIONAL DATA click TO RETURN TO INDEX here E-550 SUPER DUTY CUTAWAY Page 10 E-550 SUPER DUTY CUTAWAY 159.5I - 233.5I WHEELBASE (DRW) 1st BATTERY LOCATION SEE NOTES [28.2] 2016 [79.3] 2nd BATTERY LOCATION 2605 [102.5] 2186 [86.0] MIRRORS 1083 BUMPER 2754 [42.6]...

  • Page 13

    E-550 SUPER DUTY CUTAWAY click here TO RETURN TO INDEX VEHICLE HEIGHT DATA Page 11 E-550 SUPER DUTY CUTAWAY TIRE/GROUND CLEARANCE DATA OVERALL HEIGHT HEIGHT @ HEIGHT @ HEIGHT @ HEIGHT @ OF VEHICLE (STANDARD SPRINGS) FRONT AXLE FRONT AXLE REAR AXLE REAR AXLE COMBINED...

  • Page 14: All Wheelbases

    click here TO RETURN TO INDEX E-550 SUPER DUTY CUTAWAY ALL WHEELBASES Page 12 E-550 SUPER DUTY CUTAWAY 0.5 MIN. VEHICLE 12.7 MIN. CLEARANCE CLEARANCE [0.5] NORMAL 25.4 MIN. 27.9 TOP OF FRAME [1.0] CLEARANCE [1.1] 25.4 MIN. CLEARANCE [1.0] 25.1 25.1 [9.8]...

  • Page 15

    E-550 SUPER DUTY CUTAWAY click here TO RETURN TO INDEX 159.5I WHEELBASE FRAME DATA Page 13 E-550 SUPER DUTY CUTAWAY BODY PUCKS 1230 [48.4] 1460 [57.5] [15.0] [32.0] [24.1] [33.3] [37.4] NOTE: SPACER OPTIONS NOT AVAILABLE ON E–550. CONTACT BODY BUILDERS ADVISORY SERVICE FOR INFORMATION REGARDING THE PURCHASE OF SPACERS.

  • Page 16

    E-550 SUPER DUTY CUTAWAY click TO RETURN TO INDEX here 177.5I - 191.5I WHEELBASE Page 14 E-550 SUPER DUTY CUTAWAY FRAME DATA 1231 [48.4] 1460 [57.4] [15.0] [29.3] [20.7] [24.1] [33.3] [37.4] 177.5I WB BB0680 1353 [53.2] 1460 [57.5] [15.0] 1099 [43.2] [26.6]...

  • Page 17

    click E-550 SUPER DUTY CUTAWAY here TO RETURN TO INDEX 209.5I - 233.5I WHEELBASE Page 15 E-550 SUPER DUTY CUTAWAY FRAME DATA [12.0] 1353 [53.2] 1460 [57.4] [15.0] [28.9] [32.3] [26.6] [18.2] [33.3] [37.4] 209.5I WB BB0682 [30.0] 1353 [53.2] 1460 [57.4] [15.0]...

  • Page 18

    click here TO RETURN TO INDEX E-550 SUPER DUTY CUTAWAY 55 GALLON AFT-OF-AXLE FUEL TANK Page 16 E-550 SUPER DUTY CUTAWAY 939.8 [37.0] 374.6 [14.7] 25mm CLEARANCE IS REQUIRED BETWEEN ALL FUEL TANK COMPONENTS AND SECOND UNIT BODY. CONTACT BODY BUILDERS ADVISORY SERVICE FOR INFORMATION.

  • Page 19: Fuel Filler Systems

    click TO RETURN TO INDEX E-550 SUPER DUTY CUTAWAY here FUEL FILLER SYSTEMS Page 17 E-550 SUPER DUTY CUTAWAY E-550 CUTAWAY AFT-OF-AXLE FUEL FILLER SYSTEM C L OF FILLER NECK TO L OF REAR OUTBOARD SURFACE AXLE FOR OF FRAME RAIL ALL W.B.

  • Page 20

    click here TO RETURN TO INDEX E-550 SUPER DUTY CUTAWAY DIMENSIONAL DATA Page 18 E-550 SUPER DUTY CUTAWAY THE TORSO ANGLE IS DETERMINED BY USING THE METHOD SPECIFIED IN C L VEHICLE SAE J826 (MAY 1987) OUTSIDE 18_ DRIVER FRONT 21_ PASSENGER FASTENER TORSO ANGLE...

  • Page 21

    click E-550 SUPER DUTY CUTAWAY TO RETURN TO INDEX here BODY “SECTION A” Page 19 E-550 SUPER DUTY CUTAWAY 1.16 C L OF VEHICLE 1.97 1.20 1.16 3.94 1.18 1.16 0.77 1.97 7.87 1.03 1.00 1.97 0.92 11.81 0.83 0.75 1.97 0.35 15.75...

  • Page 22: Electrical Wiring

    click TO RETURN TO INDEX ELECTRICAL WIRING here CUSTOMER ACCESS CIRCUITS Page 20 E-550 SUPER DUTY CUTAWAY CIRCUIT CHART Circuit Color Code Wire Functional Description Number Gauge Marker lamp feed to electric brake controller Electric trailer brake controller to trailer Relay feed ignition run LB/BK Trailer brake controller or B+ feed...

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