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2002
MARCH 2002
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IMPORTANT NOTICE REFERENCE INFORMATION The specifications and designs Regulations such as those issued by the described herein are believed to be Federal Highway Administration (FHWA) correct as of the time that this book or issued pursuant to the 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 be guaranteed. They are state, provincial, and loca
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INDEX/FEATURES Index 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES Metric/U.S. Unit Equivalents . . . . . . . . . . . . . . . . . . . . 2 CHASSIS 5 wheelbase lengths 159.5, 177.5, 191.5, 209.5 and 233.5 Model Lineup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 New suspensions with GVWR availability: 17,500 pounds and 19,000 pounds Seat Reference SgRP X & Z Locations . . . . . . . . . . . 4 (front and rear suspension) Safe
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click TO RETURN TO INDEX here Page 2 E-550 SUPER DUTY CUTAWAY METRIC/U.S. CUSTOMARY UNIT EQUIVALENTS Multiply: by: to get: Multiply: by: to get: Multiply: by: to get: Multiply: by: to get: LINEAR FUEL ECONOMY inches X 25.4 = millimetres(mm) X 0.03937 = inches miles/gal X 0.4251 = kilometres/litre (km/l) X 2.352 = miles/gal inches X 2.54 = centimetres (cm) X 0.3937 = inches gal/mile X 2.3524 = litres/kilometre (l/km) X 0.42517 = gal/mile feet X 0.3048 = metres (m) X 3.281 = feet gal/mile X 235.24
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click TO RETURN TO INDEX here E-550 SUPER DUTY CUTAWAY Page 3 E-550 SUPER DUTY CUTAWAY MODEL LINEUP BASE BASE CURB CURB WEIGHT WEIGHT* * SERIES SERIES WHEELBASE WHEELBASE GVWR GVWR ST STANDARD ANDARD ENGINES ENGINES MODEL MODEL FRONT REAR TOTAL CODE mm/inches pounds TRANSMISSION liters pounds pounds pounds 6.8 3405 2785 6190 4051.3 4051.3 17 17,500/19 500/19,000 000 4R100 4R100 [159.5] 7.3 3787 2857 6644 6.8 3475 2844 6319 4508.5 4508.5 17 17,500/19 500/19,000 000 4R100 4R100 [177.5] 7.3 3857 2
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click TO RETURN TO INDEX here E-550 SUPER DUTY CUTAWAY Page 4 E-550 SUPER DUTY CUTAWAY SEAT TRACK TRAVEL/H-POINT LOCATION DRIVER DRIVER POWER TRACK MANUAL TRACK 175 FOREMOST [6.9] H POINT MID–TRACK 155 H POINT [6.1] 150 89 24 28 [5.9] [3.5] [0.9] [1.1] 10 1.4 [0.4] 51 [0.05] 41 84 [2.0] [1.6] [3.3] 168 [6.6] SgRP 178 REARMOST 10 25 13 [7.0] H POINT 10 [0.4] MID–TRACK [0.1] [0.5] [0.4] SgRP H POINT 18 33 [0.7] 208 388 REF [1.3] [8.2] [15.3] 388 REF 657 REF [15.3] [25.9] 657 REF [25.9] FRONT FIDUC
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click E-550 SUPER DUTY CUTAWAY TO RETURN TO INDEX here OCCUPANT PROTECTION SYSTEMS Page 5 E-550 SUPER DUTY CUTAWAY SEAT RESTRAINT SYSTEM 9. Seating systems should be designed to be INFORMATION SEAT SYSTEMS WARNING: compatible with the seat belt systems, so as to The following recommendations are intended to 1. For Incomplete E-Series Vans and Cutaways with permit proper adjustment, allow for occupant THE SEAT BELT BUCKLE PRETENSIONER, assist in the design of seats and seat belt systems a GVWR ov
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click E-550 SUPER DUTY CUTAWAY TO RETURN TO INDEX here 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 & VAN MODELS INTERIOR TRIM 9.5 RADIUS MIN. F7UB–1560262 RETRACTOR F7UB–1560262 COVER ASY. COVER ASY. 12.5 MIN. FRONT OF UP 1 REQ’D. EA. SIDE 1 REQ’D. EA. SIDE OVERLAP VEHICLE ADJUSTED 6.0 POSITION N806773–S190 6.5 MIN. FROM NUT – TORQUE RELEA
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click E-550 SUPER DUTY CUTAWAY 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 40.0 6.0 Nm T2007563 ZONE [29.5 4 FT-LB] SEAT 10 CLEARANCE F7UB–1561202–A ZONE 15 10 BUCKLE ASY. N801078–S424 45 SCREW M8x1.25 PIA BOLT TORQUE HEX 4 REQ’D. TORQUE 40.0 6.0 Nm [29.5 4 FT-LB] 25.0 3.8 Nm NUTS & BOLTS 4 REQ’D. [18.4 2.8 FT-LB] FOR SHIPPING A2008167 COVER FRT PURPOSES TRACK ASY. N801
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click E-550 SUPER DUTY CUTAWAY TO RETURN TO INDEX here OCCUPANT PROTECTION SYSTEMS Page 8 E-550 SUPER DUTY CUTAWAY AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM INFORMATION Ford urges careful consideration of the 3. Remove fasteners retaining driver airbag AIRBAG SUPPLEMENTAL RESTRAINT WARNING: recommendations that follow. They are based on module to steering wheel. Disconnect driver SYSTEM THE SEAT BELT BUCKLE PRETENSIONER, analyses of component and vehicle tests, actual airbag connector and remove the
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click E-550 SUPER DUTY CUTAWAY TO RETURN TO INDEX here OCCUPANT PROTECTION SYSTEMS Page 9 E-550 SUPER DUTY CUTAWAY AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM STEERING INSTRUMENT WHEEL PANEL HARNESS AIRBAG AIRBAG ELECTRONIC CRASH SENSOR MODULE READINESS INDICATOR AIRBAG USAGE CHART VEHICLE DRIVER PASSENGER E-550 Super Duty Cutaway Standard Front Standard Front CONNECTOR AT SAFETY WALL ENGINE COMPARTMENT HARNESS CRASH SENSOR DO NOT MODIFY OR ALTER ANY COMPONENTS OR AREAS DO NOT INSTALL ADDITIONAL COMPON
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click DIMENSIONAL DATA TO RETURN TO INDEX here E-550 SUPER DUTY CUTAWAY Page 10 E-550 SUPER DUTY CUTAWAY 159.5 - 233.5 WHEELBASE (DRW) 1st BATTERY LOCATION 716 SEE NOTES [28.2] 2016 [79.3] 2nd BATTERY LOCATION 2605 [102.5] 2186 [86.0] MIRRORS 1083 BUMPER 2754 [42.6] [108.4] EXTENDED 1067 [42.0] 2456 C L [96.7] VEHICLE 955 [37.6] 2203 [86.7] FLARES 55 GAL STD FUEL TANK 657 740 [25.9] [29.1] 1510 1658.9 CH [59.4] [65.3] DIMENSIONS HEIGHT OVERALL CA AF REAR OVERALL WB CA CURB LOADED 1575 DRIVER
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click E-550 SUPER DUTY CUTAWAY TO RETURN TO INDEX here VEHICLE HEIGHT DATA Page 11 E-550 SUPER DUTY CUTAWAY TIRE/GROUND CLEARANCE DATA F F R R CH OVERALL HEIGHT HEIGHT @ HEIGHT @ HEIGHT @ HEIGHT @ OF VEHICLE (1) (1) (1) (1) (1) (STANDARD SPRINGS) FRONT AXLE FRONT AXLE REAR AXLE REAR AXLE COMBINED REAR GAWR COMBINED FRONT SPRING MIN/MAX REAR SPRING CAPACITY RATE BASE CURB pounds CAPACITY RATE BASE CURB LOADED LOADED UNLOADED LOADED @ GROUND WEIGHT standard/ @ GROUND WEIGHT GVWR mm [in] mm [in] m
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click TO RETURN TO INDEX here E-550 SUPER DUTY CUTAWAY Page 12 E-550 SUPER DUTY CUTAWAY ALL WHEELBASES C L 0.5 MIN. VEHICLE 12.7 MIN. CLEARANCE CLEARANCE [0.5] TW TW 1 TH NORMAL 25.4 MIN. 27.9 TOP OF FRAME [1.0] CLEARANCE [1.1] 25.4 MIN. CLEARANCE [1.0] TH 1 25.1 25.1 C C 248 215 [9.8] [8.4] FW 212.3 [8.3] 271 195 [10.6] C 1970 L [7.6] [77.5] VEHICLE 2456 FRONT VIEW [96.7] REAR VIEW MAX. RIGHT TURN TW TH TW TW 11 L R TW L 838 213 640 668 225/70R/19.5F [33.0] [8.4] [25.2] [26.3] TW R MAX. LEFT TU
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click E-550 SUPER DUTY CUTAWAY TO RETURN TO INDEX here 159.5 WHEELBASE FRAME DATA Page 13 E-550 SUPER DUTY CUTAWAY BODY PUCKS 1230 [48.4] 1460 381 [57.5] [15.0] 813 [32.0] 613 [24.1] 847 [33.3] 952 [37.4] NOTE: SPACER OPTIONS NOT AVAILABLE ON E–550. CONTACT BODY BUILDERS ADVISORY SERVICE FOR INFORMATION REGARDING THE PURCHASE OF SPACERS. 159.5 WB BODY PUCKS (OPTIONAL) 43.5 [1.7] FREE 41.6 [1.6] FREE SHIPPED IN DUNNAGE (32.6 [1.2] w/LOAD) (32.6 [1.2] w/LOAD) 48.9 FREE 47.0 FREE [1.9] STATE
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click E-550 SUPER DUTY CUTAWAY TO RETURN TO INDEX here 177.5 - 191.5 WHEELBASE Page 14 E-550 SUPER DUTY CUTAWAY FRAME DATA 1231 [48.4] 1460 381 [57.4] [15.0] 743 [29.3] 527 [20.7] 613 [24.1] 847 [33.3] 952 [37.4] 177.5 WB BB0680 1353 [53.2] 1460 381 [57.5] [15.0] 1099 [43.2] 677 [26.6] 462 [18.2] 847 [33.3] 952 [37.4] NOTE: SPACER OPTIONS NOT AVAILABLE ON E–550. CONTACT BODY BUILDERS ADVISORY SERVICE FOR INFORMATION REGARDING THE PURCHASE OF SPACERS. 191.5 WB BB0681 NOTE [ ] DIMENSIONS
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click E-550 SUPER DUTY CUTAWAY TO RETURN TO INDEX here 209.5 - 233.5 WHEELBASE Page 15 E-550 SUPER DUTY CUTAWAY FRAME DATA 305 [12.0] 1353 [53.2] 1460 381 [57.4] [15.0] 734 [28.9] 822 [32.3] 677 [26.6] 462 [18.2] 847 [33.3] 952 [37.4] 209.5 WB BB0682 762 [30.0] 1353 [53.2] 1460 [57.4] 381 [15.0] 1344 [52.9] 822 [32.3] 677 [26.6] 462 [18.2] 847 [33.3] 952 [37.4] NOTE: SPACER OPTIONS NOT AVAILABLE ON E–550. CONTACT BODY BUILDERS ADVISORY 233.5 WB SERVICE FOR INFORMATION REGARDING THE PURCHA
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click TO RETURN TO INDEX here E-550 SUPER DUTY CUTAWAY Page 16 E-550 SUPER DUTY CUTAWAY 55 GALLON AFT-OF-AXLE FUEL TANK A 939.8 [37.0] 374.6 [14.7] A 25mm CLEARANCE IS REQUIRED BETWEEN ALL FUEL TANK COMPONENTS AND SECOND UNIT BODY. CONTACT BODY BUILDERS C L ADVISORY SERVICE FOR INFORMATION. FUEL FILL 822.9 40.6 [32.4] [1.6] A 363.2 [14.3] 330.2 [13.0] 988.0 [38.9] C L REAR AXLE BB0693 NOTE [ ] DIMENSIONS ARE INCHES.
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click TO RETURN TO INDEX here E-550 SUPER DUTY CUTAWAY Page 17 E-550 SUPER DUTY CUTAWAY FUEL FILLER SYSTEMS E-550 CUTAWAY AFT-OF-AXLE FUEL FILLER SYSTEM C L OF FILLER NECK C TO L OF REAR OUTBOARD SURFACE AXLE FOR OF FRAME RAIL ALL W.B. 823 5 [32.4] FRONT OF 3 VEHICLE 1 FRONT OF VEHICLE 2 4 6 733.4 TORQUE SEQUENCE [28.875] SCREW 3 REQ’D. TORQUE TO 2.1 – 2.9 Nm 18 – 26 IN LB. TOP OF FUEL TANK FILLER PIPE SUPPORT SECURE WITH TIE 323.2 [12.72] STRAPS AS REQUIRED TO VENT HOSE POINT Z SEE PAGE 59
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click TO RETURN TO INDEX here E-550 SUPER DUTY CUTAWAY Page 18 E-550 SUPER DUTY CUTAWAY DIMENSIONAL DATA THE TORSO ANGLE IS DETERMINED BY USING THE METHOD SPECIFIED IN C VEHICLE L SAE J826 (MAY 1987) C OUTSIDE L 18 DRIVER FRONT 21 PASSENGER FASTENER D TORSO ANGLE E E POINT A POINT A POINT A H61 A W3 W5 F W117 L34 C B B SEAT BACK SEAT PIVOT 6.0 BASE [0.24] SgRP - HAS A 12.7 [0.50] RADIAL SEAT C OUTSIDE C OUTSIDE L L TOLERANCE PERMITTED FROM BASE FRONT FRONT BASE SgRP FASTENER FASTENER 510.0 HEE
