Ford 1 - Manual

General Information 1-1 Section 1: General Information Important Safety Notice Note: The descriptions and specifications contained in this guide were in effect at the time thismanual was approved for printing. Ford Motor Company reserves the right to discontinuemodels at any time, or change specific...

1-2 General Information Section 1: General Information The following list contains some general warnings that you should follow when you work on avehicle. WARNING: • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires you to be under the vehicle. • Make s...

General Information 1-3 Section 1: General Information Special Service Vehicle (SSV) Definition Special Service Vehicles (SSV) are offered to fill the special needs of police agencies that astandard patrol car can not. SSV Standard Package Deletes Item Floor console Floor mats Fog lamps Third-row se...

General Information 1-5 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 Fir...

1-6 General Information Section 1: General Information Vehicle Certification (VC) Label Code Positions Position Description 1 Exterior paint code 2 Region code 3 District Special Order (DSO) 4 Wheelbase code 5 Interior trim code 6 Tape/paint pinstripe code 7 Radio code 8 Axle code 9 Transmission cod...

General Information 1-7 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 setof letters/numbers listed (if applicable) indicate a 2-tone or accent body color code. • DX — Dark Blue Pearl • UG —...

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 andunderside of front fender. • Periodically wash vehicles stored in exposed locations. • Touch up exposed raw or primed metal t...

General Information 1-11 Section 1: General Information Tire Pressure Monitoring System (TPMS) Principles of Operation The tire pressure monitoring system (TPMS) monitors the air pressure of all 4 regular road tires.The tire pressure sensors, attached to each rim by a metal band located in the drop ...

1-12 General Information Section 1: General Information The TPMS, as delivered from the Ford Motor Company, complies with part 15 of the FCC rulesand with RS-210 of Industry Canada. Operation is subject to the following 2 conditions: • This device may not cause harmful interference • This device mus...

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 cer...

Electrical 2-1 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 thewires are outlets in the form of lights, switches and rec...

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

Electrical 2-3 Section 2: Electrical Component Amps Base Miscellaneous Base Loads 16.5 Cooling Cooling Fan (electric fan clutch) 2.2 Climate Control A/C Clutch 3.5 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 8.5 ...

2-4 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 ...

Electrical 2-5 Section 2: Electrical • Disconnect the negative battery cable of vehicles stored on site to reduce the possibility ofdraining the battery by lights or other equipment. • Do not allow control panels attached to the instrument panel to protrude into the driver andpassenger air bag deplo...

2-6 Electrical Section 2: Electrical Equipment Grounding Guidelines • Do not ground the body to the transmission or transmission crossmember. Ground accessoriesto the chassis or the vehicle battery. • Splicing into circuitry relating to the electronic engine and/or transmission control systems is no...

Electrical 2-7 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...

2-8 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) an...

Electrical 2-9 Section 2: Electrical • Use greased or sealed connectors in floor pan troughs which are subject to moisture comingthrough the carpeting. • Use XLPE insulation for uncovered runs that exceed 305 mm (12 in). Electrical Protection • Correctly route wires away from noise-generating wires ...

2-10 Electrical Section 2: Electrical • Scroll — Similar to convolute, but without the ridges. Scroll is used where harness rigidity isrequired, 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-i...

Electrical 2-11 Section 2: Electrical • Route wires to avoid metal edges, screws, trim fasteners and abrasive surfaces. When suchrouting is not possible, use protective devices (shields, caps) to protect the wires. Cover metaledges with a protective shield and fasten the wiring within 76 mm (3 in) o...

2-12 Electrical Section 2: Electrical Wire Retention and Routing Use the following criteria to determine the location of retainers: • Size and weight of wire bundle. • Holes with poor accessibility that prevent installation of locators. • Movement of wires that can result in abrasion, squeaks and ra...

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 damagevehicle components, including wiring, brake lines, fuel tank and lines, powertrain components,exhaust system an...

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 onstraight areas as installed, not on bends. • Strip wir...

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. Ben...

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. 2010 Expedition SSV Modifiers Guide, 07/2009

Electrical 2-17 Section 2: Electrical 9. Reconnect the battery ground cable. Sealed Connectors Ford Part Number Part Name Class E6FZ-14488-A Butt Connector C Gauge: 18-22, Color: Red E6FZ-14488-B Butt Connector C Gauge: 14-16, Color: Blue E6FZ-14488-C Butt Connector C Gauge: 10-12, Color: Yellow Hea...

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. 1...

2-20 Electrical Section 2: Electrical Rear Power Window Disable The rear power windows of the Expedition SSV can be disabled by disconnecting the rear windowmotor connectors (C701 [LH] and C801 [RH]). These connectors are located inside the door,behind the door trim panel. While they are disabled, t...

Installation Considerations 3-1 Section 3: Installation Considerations Mobile Radio Installation Guidelines NOTICE: This information has been prepared for use by persons installing 2-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current enginee...

3-2 Installation Considerations Section 3: Installation Considerations Radio transmitters are regulated by the Federal Communications Commission (FCC) in the UnitedStates. Compliance with FCC regulations is the responsibility of the manufacturer and/or user oftransmitter equipment and not Ford Motor...

Installation Considerations 3-3 Section 3: Installation Considerations Glass-mounted antennas should be kept as high as possible in the center of the rear window orwindshield. Some vehicles use glass that contains a thin metallic coating for defrosting or tocontrol solar gain; glass mount antennas m...

3-4 Installation Considerations Section 3: Installation Considerations If any vehicle radio interaction problems exist after following these guidelines, contact the radioequipment manufacturer for additional assistance. Additional Sources of Information Radio Frequency Interference: How to Find It a...

Installation Considerations 3-5 Section 3: Installation Considerations Item Description 1 Side curtain tether anchor bolt hole 2 A-pillar assist handle bracket lower mounting bolt hole 3 Center line 4 Spotlight shaft hole 5 Spotlight mount lower bolt hole 1. Mark a center line between the center of ...

3-6 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 itscorrect operating temperature. When adding sirens and grille lights to a vehicle, make sure thisairflow is ...

Installation Considerations 3-7 Section 3: Installation Considerations Safety Belt Retractor and Side Impact Sensor Item Description 1 Side impact sensor 2 Front safety belt retractor The front safety belt retractors are located in the base of the B-pillars. The pretensioner located inthe buckle is ...

3-8 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 ...

Installation Considerations 3-9 Section 3: Installation Considerations Driver/passenger air bags affect the way police equipment can be mounted in police vehicles. Anysurfaces that could come into contact with an air bag during deployment must not damage the airbag or alter its deployment path. Shar...

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)..................................

Cargo Mounting Considerations 4-1 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...

Cargo Mounting Considerations 4-3 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 i...

4-4 Cargo Mounting Considerations 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 org...

Cargo Mounting Considerations 4-5 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, safetyrope, tow strap, traffic cones ...

Reference Information 5-1 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-moun...

5-4 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. • Do not mount equipment to the A-pillar above the beltli...

Reference Information 5-5 Section 5: Reference Information Fuel Lines — Short Wheelbase Item Description 1 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009

Reference Information 5-7 Section 5: Reference Information Fuel Tank — Cut View, Short Wheelbase Item Description 1 Evaporative emissions hose 2 Fuel tank 3 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009

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...

5-14 Reference Information Section 5: Reference Information Item Description 1 Master cylinder 2 Brake booster 3 Brake lines 4 Brake control module Technical Specifications Item Specification Specification Make: Ford Model: Expedition Special Service Sales Code: — Vehicle (SSV) Engine Displacement C...