User Guide for Ford models including: F-150, Police Responder Pickup, Responder Pickup, Police Responder, Responder
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DocumentDocument2021 - 2022 F-150 Police F-150 SECTION 0: Introduction Table of Contents Contents PAGE Introduction ................................................................................................................................................................................... 0-2 Genuine Ford Accessories For Your Vehicle .......................................................................................................................... 0-2 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 © Copyright Ford 2021 FoMoCo 0-2 Introduction Introduction Introduction Ford Motor Company has assembled this Modifier Guide to assist vehicle modifiers in producing safe and quality products. Ford believes that safety and quality come first. To achieve customer satisfaction, we want to assist modifiers in achieving the highest standards of safety and quality in their products. This book is divided into topics pertinent to modifiers of police vehicles. Reference is made to the current Workshop Manual for appropriate service procedures, torque specifications, component separation clearances and other standard information which is common with the unmodified vehicle. Specifications which are unique to the guide are designated. This modifier guide is not a "how-to" book; it should be used as a checklist to help make sure that certain important steps in the modification process are considered. While Ford is providing this information to assist modifiers, it does not warrant the products, methods, materials or the workmanship of the modifier. Nor does it warrant against failures that result from the modification of a vehicle. Following the guidelines contained in this guide it does not assure individual modifiers that the products they modify comply with U.S. Federal or Canadian Motor Vehicle Safety Standards in effect at the time of the modification. The guidelines set forth are based on engineering analyses of typical police vehicles. If followed, the modifier's efforts in certifying vehicles to applicable standards should be aided. Compliance testing that may be required for certification of specific vehicle configurations or construction is, however, the sole responsibility of the individual modifier. The only model suitable for use in police service is the pursuit-rated Police Interceptor. DuPontTM and KEVLAR® are trademarks or registered trademarks of DuPontTM or its affiliates. Genuine Ford Accessories For Your Vehicle A wide selection of genuine Ford accessories are available for your vehicle through your local authorized Ford or Ford of Canada dealer. These quality accessories have been specifically engineered to fulfill your automotive needs; they are custom designed to complement the style and aerodynamic appearance of your vehicle. In addition, each accessory is made from high-quality materials that meet or exceed Ford's rigorous engineering and safety specifications. Ford Motor Company will repair or replace any properly installed genuine Ford accessory found to be defective in factory-supplied materials or workmanship during the warranty period, as well as any component damaged by the defective accessory. The accessory will be warranted for whichever provides you the greatest benefit: · 12 months or 20,000 km (12,000 mi), whichever occurs first; or · the remainder of your new vehicle limited warranty. This means that genuine Ford accessories purchased along with your new vehicle and installed by the dealer are covered for the full length of your new vehicle's limited warranty -- 3 years or 60,000 km (36,000 mi), whichever occurs first. Contact your dealer for details and a copy of the warranty. Considerations When Using or Installing Accessories For maximum vehicle performance, keep the following information in mind when adding accessories or equipment to your vehicle: · When adding accessories, equipment, passengers and/or luggage to your vehicle, do not exceed the gross vehicle weight rating (GVWR) or gross axle weight rating (GAWR) as indicated on the Safety Compliance Certification Label. Consult your dealer for specific weight information. · The Federal Communications Commission (FCC) and Canadian Radio Telecommunications Commission (CRTC) regulates the use of mobile communication systems, such as 2-way radios, telephones and theft alarms that are equipped with radio transmitters. Any such equipment installed in your vehicle should comply with FCC or CRTC regulations and should only be installed by a qualified service technician. · Mobile communication systems may harm the operation of your vehicle, particularly if they are not properly designed for automotive use. · To avoid interference with other vehicle functions, such as the anti-lock brake system (ABS), amateur radio users who install radios and antennas onto their vehicle should not locate the antenna in the area of the driver's side hood. · Electrical or electronic accessories or components that are added to the vehicle by the dealer or the owner may adversely affect battery performance and durability. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 © Copyright Ford 2021 FoMoCo SECTION 1: General Information Table of Contents Contents PAGE Section 1: General Information ..................................................................................................................................................... 1-2 Important Safety Notice .......................................................................................................................................................... 1-2 Police Vehicle Definition ......................................................................................................................................................... 1-3 Good Practices ....................................................................................................................................................................... 1-3 New Vehicle Storage .............................................................................................................................................................. 1-3 Police Vehicle Definition ......................................................................................................................................................... 1-4 Tires and Loading ................................................................................................................................................................... 1-4 Ambient Temperature Change and Tire Pressure .................................................................................................................. 1-6 Ride Height Measurement -- Front ........................................................................................................................................ 1-7 Ride Height Measurement -- Rear ......................................................................................................................................... 1-9 Ride Height Specifications ...................................................................................................................................................... 1-9 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 1-2 Section 1: General Information General Information Section 1: General Information Important Safety Notice NOTE: The descriptions and specifications contained in this guide were in effect at the time this guide 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. Appropriate repair methods and procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This guide provides general direction and guidelines for performing modifications to the vehicle, which will help assure reliability. There are numerous variations in procedures, techniques, tools and parts for modifying vehicles, as well as in the skill level of the individual doing the work. This guide cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this guide must first establish that they compromise neither their personal safety nor the vehicle integrity by the choice of methods, tools or parts. Warnings, Notices and Notes As you read through this guide, you will come across WARNINGS, NOTICES and NOTES. Each one is there for a specific purpose. WARNINGS remind you to be especially careful in those areas where carelessness can cause you personal injury. NOTICES are given to prevent you from making an error that could damage the vehicle or the vehicle's components. NOTES give you added information that will help you to complete a particular procedure. The following list contains some generalized warnings that you should follow when working on a vehicle. WARNING: · For eye protection, always wear safety glasses. · Use safety stands whenever a procedure requires you to be under the vehicle. · Make sure the ignition switch is always in the OFF position, unless otherwise required by the procedure. · Set the parking brake when working on the vehicle. The gear selector should be set in PARK unless instructed otherwise for a specific operation. Place wood blocks (4 inch x 4 inch or larger) against the front and rear surfaces of the tires to help prevent the vehicle from moving. · Do not smoke while working on a vehicle. · To reduce the risk of injury, always remove rings, watches, loose hanging jewelry and loose clothing before working on a vehicle. · When it is necessary to work under the hood, keep hands and other objects clear of the cooling fan blades. · Failure to follow these instructions may result in personal injury or death. NOTICE: · Do not modify the cooling system. High voltage vehicle components may be damaged if any cooling system modifications are attempted. · Before placing the vehicle in a paint booth, make sure that the HVTB is not installed in the vehicle. In addition, the Charge Port Light Ring (CPLR) must be covered / protected from heat. High paint booth temperatures may damage the HVTB and the CPLR. · Remove the service disconnects while carrying out any vehicle modifications. Making Safety Devices and Elements Inoperative The vehicle contains many safety features required by US Federal or Canadian Motor Vehicle Safety Standards. These features, which include the key-on-ignition chime and brake lights, should never be disabled or modified. CFR 49 Section 30122 states that "A manufacturer, distributor, dealer or motor vehicle repair business may not knowingly make inoperative any part of a device or element of design installed on or in a motor vehicle or motor vehicle's equipment in compliance with an applicable motor vehicle safety standard prescribed under this chapter unless the manufacturer, distributor, dealer or repair business reasonably believes the vehicle or equipment will not be used (except for testing or a similar purpose during maintenance or repair) when the device or element is inoperative." 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 General Information 1-3 Section 1: General Information Police Vehicle Definition The Police Interceptor vehicle is put through twice as many cycles of Ford's standard vehicle durability tests to make sure it meets the rigors of police usage. This vehicle testing is in addition to substantial component durability testing. This extra testing for the Police Interceptor certifies to Ford the entire vehicle is "heavy-duty" and suitable for police usage. Good Practices Process And Quality Assurance Systems A formalized Process and Quality Assurance system may be helpful in consistently producing high quality products. An overview of some of the key items for such a system are outlined in this section. Quality Assurance Completed Unit Sign-Off: All control items should be inspected with a written sign-off. All labels should be inspected and signed off, including verification the information on the labels is correct. All appropriate systems should be checked for leaks. A road test should be performed to verify that all systems are operating correctly. All systems and functions that were provided by Ford should be checked to make sure they function correctly after the build process. The modifier's Process and Quality Assurance Systems should also assure that appropriate training is provided to the employees. Minimum And Maximum Screw Sizes When installing aftermarket equipment, 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. New Vehicle Storage New Vehicle Storage -- General · Vehicle should be stored in a dry, ventilated place, and protected from sunlight, if possible. · If vehicle is stored outside, maintenance against rust and damage, as described below, is recommended. NOTICE: Keep all rubber parts free from oil and solvents. 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 if vehicle is stored in exposed locations. · Touch up exposed raw or primed metal to provide rust protection. · Cover chrome and stainless steel parts with a thick coat of auto wax to prevent discoloration. Rewax as necessary when the vehicle is washed. · Lubricate all hood, door hinges and latches with a light grade oil. · Cover the interior soft trim to prevent fading. New Vehicle Storage -- Engine · Start the engine every 15 days. Run it at fast idle until it reaches normal operating temperature. · With foot on brake pedal (and brake applied), shift the transmission into all gears while the engine is running. New Vehicle Storage -- Fuel System · Regularly move vehicle short distances to mix fuel anti-oxidation agents. NOTE: During extended periods of vehicle storage (60 days or more), gasoline may deteriorate due to oxidation. This can damage rubber and other polymers in the fuel system and may clog small orifices. A commercially available gasoline fuel stabilizer (Sta-Bil or equivalent) should be added to gasoline-powered vehicles whenever actual or expected storage periods exceed 60 days. The manufacturer's instructions packaged with the product should be followed. The vehicle should then be operated at an idle speed to circulate the additive throughout the fuel system. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 1-4 Section 1: General Information General Information New Vehicle Storage -- Tires Most high performance tires are made with nylon overlay. As such, the following steps should be taken to avoid flat spotting when the vehicle is not used for a period of time. · Keep the vehicles tire pressure at the recommended operating pressure. · If the vehicle is stored for a period longer than 15 days, it should be moved several feet during each 15-day period. The vehicle should be parked after being moved so that a different portion of the tread contacts the ground. Police Vehicle Definition The Police Interceptor vehicle is put through twice as many cycles of Ford's standard vehicle durability tests to make sure it meets the rigors of police usage. This vehicle testing is in addition to substantial component durability testing. This extra testing for the Police Interceptor certifies to Ford the entire vehicle is "heavy-duty" and suitable for police usage. For standard features and options please refer to www.fleet.ford.com Tires and Loading Tire Replacement Requirements WARNING: Only use replacement tires and wheels that are the same size and type (such as P-metric versus LT-metric or all-season versus allterrain) as those originally provided by Ford. Use of any tire or wheel not recommended by Ford can affect the safety and performance of your vehicle, which could result in an increased risk of the loss of vehicle control, vehicle rollover, personal injury or death. Additionally, the use of non-recommended tires and wheels could cause steering or suspension failure. If you have questions regarding tire replacement, see an authorized Ford or Lincoln dealer. NOTICE: Do not install an off road, aggressive tread or incorrectly sized tire. Any of these may cause elevated stress to the steering system. This can cause the power steering system to overheat and shut off the power assist, which can affect the safety and performance of your vehicle. NOTE: Vehicles are equipped with a reduced rolling resistance tire design. The use of a different tire can affect the travel distance of the vehicle as well as the vehicle's fuel economy. Make sure all tires and wheels on the vehicle are of the same size, type, tread design, brand, load-carrying capacity and speed rating because it can affect the safety and performance of your vehicle, which could result in an increased risk of loss of vehicle control. Tire Pressure Monitoring System (TPMS) Principles of Operation The TPMS monitors the tire pressure using 4 valve stem mounted TPMS sensors to provide accurate tire pressures. Each individual sensor contains its own battery and transmits tire pressure data to the controlling module every 60 seconds when the vehicle speed exceeds 32 km/h (20 mph). The TPM module is a radio receiver that collects the tire pressure data and relays the information via the MS-CAN to the BCM. All of the TPMS functions are controlled by the BCM. The TPMS sensors are trained to the BCM, which records each TPMS sensors unique identifier. The BCM records where each TPMS sensor is located based on the training order and compares the actual tire pressure with the desired tire pressure as indicated on the Vehicle Certification label. If the tire pressure deviates from the desired tire pressure the BCM, using the HS-CAN, signals the IPC to illuminate the TPMS warning indicator and also displays a message on the message center. The programmed tire pressure cannot be changed. This vehicle, as delivered by Ford Motor Company, conforms to Standard FMVSS138, Tire Pressure Monitoring Systems. This system may not function if any of the following components are removed, relocated or modified in any way: · Original Equipment Manufacturer (OEM) wheels and tires · Tire pressure sensors or valve stems · Body Control Module (BCM) · Body Control Module (BCM) software and calibrations · Tire Pressure Module (TPM) · Instrument Cluster (IC) module · Instrument Cluster (IC) software and calibrations · Vehicle wheelbase longer than originally released 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 General Information 1-5 Section 1: General Information Certain modification could cause reduced system performance, up to and including the complete loss of TPMS functionality. This may include: · Non-OEM wheels or tires · The addition of steel carcass or run-flat tires · Modification of the vehicle's recommended tire pressure · Lengthening of the vehicle's wheelbase may affect signal strength of the sensors to a point where the rear sensors can no longer be heard by the TPM module. (Vehicles certified at released wheelbases only) · The addition of metallic structures, such as prisoner partitions, may affect the signal strength of the sensors and could interfere or prevent the TPM module from hearing the rear sensors. · The addition of intended or unintended transmitters to the vehicle may affect the signal strength of the sensors or interfere with the TPM module's antenna 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, and · This device must accept any interference received, including interference that may cause undesired operation. Using Snow Tires and Traction Devices NOTE: Snow tires must be the same size and grade as originally equipped on your vehicle. The tires on your vehicle have all-weather tread to provide traction in the rain and snow; however, in some climates, using snow tires or traction devices may be necessary. Follow these guidelines when using snow tires and traction devices: · SAE Class "S" cables should ONLY be used on the vehicle front tires. · Install cables or chains securely, verifying that the cables or chains do not touch any wiring or brake lines. · Drive cautiously! If you hear the cables or chains rub or bang against the vehicle, stop and retighten them. If this does not work, remove the cables or chains to prevent vehicle damage. · Avoid overloading your vehicle. · Remove the cables or chains when they are no longer needed. Do not use cables or chains on dry roads. · Do not exceed 48 km/h (30 mph) with tire cables or chains on your vehicle. Consult your dealer for information on other Ford approved methods of traction control. Vehicle Loading WARNING: The appropriate loading capacity of your vehicle can be limited either by volume capacity (how much space is available) or by payload capacity (how much weight the vehicle should carry). Once you have reached the maximum payload of your vehicle, do not add more cargo, even if there is space available. Overloading or improperly loading your vehicle can contribute to the loss of vehicle control and vehicle rollover. WARNING: Exceeding the Safety Compliance Certification Label axle and/or vehicle weight rating limits could result in substandard vehicle handling or performance, engine, transmission and/or structural damage, serious damage to the vehicle, loss of control and personal injury. Gross vehicle weight rating (GVWR) is the maximum allowable weight of the fully loaded vehicle (including all options, equipment, passengers and cargo). The GVWR is shown on the Safety Compliance Certification Label located on the B-pillar or the edge of the driver's door. Gross axle weight rating (GAWR) is the maximum allowable weight that can be carried by a single axle (front or rear). These numbers are shown on the Safety Compliance Certification Label located on the B-pillar or the edge of the driver's door. The total load on each axle must never exceed its GAWR. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 1-6 Section 1: General Information General Information WARNING: Do not use replacement tires with lower load carrying capacities than the original tires because they may lower the vehicle's gross vehicle weight rating (GVWR) and gross axle weight rating (GAWR) limitations. Replacement tires with a higher limit than the originals do not increase the GVWR and GAWR limitations. Steps for determining the correct load limit: · Locate the statement "The combined weight of occupants and cargo should never exceed XXX kg or XXX lb" on your vehicle's placard. · Determine the combined weight of the driver and passengers that will be riding in your vehicle. · Subtract the combined weight of the driver and passengers from XXX kg or XXX lb. · The resulting figure equals the available amount of cargo and luggage load capacity. For example, if the "XXX" amount equals 1,400 lb and there will be five 150 lb passengers in your vehicle, the amount of available cargo and luggage load capacity is 650 lb (1400 - 750 (5 x 150) = 650 lb). In metric units (635 - 340 (5 x 68) = 295 kg). · Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not safely exceed the available cargo and luggage load capacity calculated in the step above. Ambient Temperature Change and Tire Pressure NOTICE: Do not inflate tire higher than maximum pressure stamped on tire sidewall. Premature tire wear or damage to the tire may result. Tire pressures fluctuate with temperature changes. For this reason, tire pressure must be set to specification when tires are at outdoor ambient temperatures. If the vehicle is allowed to warm up to shop temperatures, and the outside temperature is less than shop temperature, the tire inflation pressure must be adjusted accordingly. If the tires are inflated to specification at shop temperatures, and the vehicle is moved outdoors when the outdoor ambient temperature is significantly lower, the tire pressure may drop enough to be detected by the TPMS and activate the TPMS warning lamp. 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 label pressure. Refer to the following tables to adjust the tire pressure indoors for colder outside temperatures. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 General Information 1-7 Section 1: General Information Ride Height Measurement -- Front 1. NOTE: Make sure that the vehicle is positioned on a flat, level surface. Jounce front and rear suspension vigorously to allow the vehicle to settle. 2. Before measuring ride height check: a. Tires are inflated to the correct pressure. b. Vehicle should have at least one-half tank of fuel. c. All fluids at proper levels. d. No cargo inside the cab or bed. e. Inspect for aftermarket equipment. Check for aftermarket changes to the steering, suspension, wheel and tire components (such as competition, heavy duty, etc.). 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 1-8 Section 1: General Information General Information 3. Ride height = 2-3 (Use the General Equipment: Surface Gauge) ·Measure the distance between the flat level surface and the center of the rearward lower arm bolt. (measurement 2) ·Measure the distance between the flat level surface and the lowest point on the wheel knuckle. (measurement 3) 4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement 2) and (measurement 3). 5. Subtract measurement 3 from measurement 2 to obtain the front ride height. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 General Information 1-9 Section 1: General Information Ride Height Measurement -- Rear 1. NOTE: Make sure that the vehicle is positioned on a flat, level surface, transmission in the PARK position and the parking brake OFF. Jounce front and rear suspension vigorously to allow the vehicle to settle. 2. Before measuring ride height check: a. Tires are inflated to the correct pressure. b. Vehicle should have at least one-half tank of fuel. c. All fluids at proper levels. d. No cargo inside the cab or bed. e. Inspect for aftermarket equipment. Check for aftermarket changes to the steering, suspension, wheel and tire components (such as competition, heavy duty, etc.). 3. Measure the distance between the top of the rear axle tube (Item 3) and the rear axle jounce stop (Item 2) to obtain the rear ride height (Item 1). (Use the General Equipment: Surface Gauge) Ride Height Specifications Ride Height -- Four-Wheel Drive (4WD) Crew Cab -- Heavy Duty Item 145-in wheelbase, 3.5L GTDI Front Specification 114 mm (4.488 in) ± 12 mm (0.472 in) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 1-10 Section 1: General Information General Information Ride Height -- Four-Wheel Drive (4WD) Crew Cab -- Heavy Duty (Continued) Rear 164 mm (6.456 in) ± 12 mm (0.472 in) 145-in wheelbase, 5.0L Front 122 mm (4.803 in) ± 12 mm (0.472 in) Rear 162 mm (6.535 in) ± 12 mm (0.472 in) 157-in wheelbase, 3.5L GTDI Front 119 mm (4.685 in) ± 12 mm (0.472 in) Rear 159 mm (6.259 in) ± 12 mm (0.472 in) 157-in wheelbase, 5.0L Front 115 mm (4.527 in) ± 12 mm (0.472 in) Rear 166 mm (6.535 in) ± 12 mm (0.472 in) Ride Height -- Four-Wheel Drive (4WD) Super Cab -- Heavy Duty Item 145-in wheelbase, 3.5L GTDI Front Rear 145-in wheelbase, 5.0L Front Rear 163-in wheelbase, 3.5L GTDI Front Rear 163-in wheelbase, 5.0L Front Rear Specification 122 mm (4.803 in) ± 12 mm (0.472 in) 159 mm (6.259 in) ± 12 mm (0.472 in) 124 mm (4.881 in) ± 12 mm (0.472 in) 165 mm (6.496 in) ± 12 mm (0.472 in) 124 mm (4.881 in) ± 12 mm (0.472 in) 162 mm (6.377 in) ± 12 mm (0.472 in) 126 mm (4.960 in) ± 12 mm (0.472 in) 157 mm (6.181 in) ± 12 mm (0.472 in) Ride Height -- Four-Wheel Drive (4WD) Crew Cab -- Heavy Duty -- Max TT Item 145-in wheelbase, 3.5L GTDI Front Rear 145-in wheelbase, 5.0L Front Rear 157-in wheelbase, 3.5L GTDI Front Rear 157-in wheelbase, 5.0L Front Specification 121 mm (4.763 in) ± 12 mm (0.472 in) 171 mm (6.732 in) ± 12 mm (0.472 in) 129 mm (5.078 in) ± 12 mm (0.472 in) 170 mm (6.692 in) ± 12 mm (0.472 in) 116 mm (4.566 in) ± 12 mm (0.472 in) 167 mm (6.574 in) ± 12 mm (0.472 in) 112 mm (4.409 in) ± 12 mm (0.472 in) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 General Information 1-11 Section 1: General Information Ride Height -- Four-Wheel Drive (4WD) Crew Cab -- Heavy Duty -- Max TT (Continued) Rear 173 mm (6.811 in) ± 12 mm (0.472 in) Ride Height -- Four-Wheel Drive (4WD) Super Cab -- Heavy Duty-- Max TT Item 163-in wheelbase, 5.0L Front Rear Specification 124 mm (4.881 in) ± 12 mm (0.472 in) 165 mm (6.496 in) ± 12 mm (0.472 in) Ride Height -- Four-Wheel Drive (4WD) Crew Cab -- Heavy Payload Package -- (18" Wheels) Item 157-in wheelbase, 3.5L GTDI Front Rear 157-in wheelbase, 5.0L Front Rear Specification 121 mm (4.763 in) ± 12 mm (0.472 in) 180 mm (7.086 in) ± 12 mm (0.472 in) 121 mm (4.763 in) ± 12 mm (0.472 in) 181 mm (7.125 in) ± 12 mm (0.472 in) Ride Height -- Four-Wheel Drive (4WD) Super Cab -- Heavy Payload Package -- (18" Wheels) Item 163-in wheelbase, 3.5L GTDI Front Rear 163-in wheelbase, 5.0L Front Rear Specification 126 mm (4.960 in) ± 12 mm (0.472 in) 178 mm (7.047 in) ± 12 mm (0.472 in) 127 mm (5.000 in) ± 12 mm (0.472 in) 179 mm (7.047 in) ± 12 mm (0.472 in) Ride Height -- Rear Wheel Drive (RWD) Crew Cab -- Heavy Duty Item 145-in wheelbase, 3.5L GTDI Front Rear 145-in wheelbase, 5.0L Front Rear 157-in wheelbase, 3.5L GTDI Front Rear 157-in wheelbase, 5.0L Front Specification 118 mm (4.645 in) ± 12 mm (0.472 in) 158 mm (6.220 in) ± 12 mm (0.472 in) 119 mm (4.685 in) ± 12 mm (0.472 in) 162 mm (6.377 in) ± 12 mm (0.472 in) 117 mm (4.606 in) ± 12 mm (0.472 in) 160 mm (6.299 in) ± 12 mm (0.472 in) 119 mm (4.685 in) ± 12 mm (0.472 in) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 1-12 Section 1: General Information General Information Ride Height -- Rear Wheel Drive (RWD) Crew Cab -- Heavy Duty (Continued) Rear 164 mm (6.456 in) ± 12 mm (0.472 in) Ride Height -- Rear Wheel Drive (RWD) Super Cab -- Heavy Duty Item 145-in wheelbase, 3.5L GTDI Front Rear 145-in wheelbase, 5.0L Front Rear 163-in wheelbase, 3.5L GTDI Front Rear 163-in wheelbase, 5.0L Front Rear Specification 118 mm (4.645 in) ± 12 mm (0.472 in) 162 mm (6.377 in) ± 12 mm (0.472 in) 120 mm (4.724 in) ± 12 mm (0.472 in) 166 mm (6.535 in) ± 12 mm (0.472 in) 123 mm (4.842 in) ± 12 mm (0.472 in) 170 mm (6.692 in) ± 12 mm (0.472 in) 126 mm (4.960 in) ± 12 mm (0.472 in) 164 mm (6.456 in) ± 12 mm (0.472 in) Ride Height -- Four-Wheel Drive (RWD) Crew Cab -- Heavy Duty -- Max TT Item 145-in wheelbase, 3.5L GTDI Front Rear 145-in wheelbase, 5.0L Front Rear 157-in wheelbase, 3.5L GTDI Front Rear 157-in wheelbase, 5.0L Front Rear Specification 116 mm (4.566 in) ± 12 mm (0.472 in) 166 mm (6.535 in) ± 12 mm (0.472 in) 120 mm (4.724 in) ± 12 mm (0.472 in) 170 mm (6.692 in) ± 12 mm (0.472 in) 120 mm (4.724 in) ± 12 mm (0.472 in) 167 mm (6.574 in) ± 12 mm (0.472 in) 119 mm (4.685 in) ± 12 mm (0.472 in) 171 mm (6.732 in) ± 12 mm (0.472 in) Ride Height -- Rear Wheel Drive (RWD) Super Cab -- Heavy Duty -- Max TT Item 163-in wheelbase, 5.0L Front Rear Specification 122 mm (4.803 in) ± 12 mm (0.472 in) 171 mm (6.732 in) ± 12 mm (0.472 in) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 General Information 1-13 Section 1: General Information Ride Height -- Rear Wheel Drive (RWD) Crew Cab -- Heavy Payload Package -- (18" Wheels) Item 157-in wheelbase, 3.5L GTDI Front Rear 157-in wheelbase, 5.0L Front Rear Specification 111 mm (4.370 in) ± 12 mm (0.472 in) 179 mm (7.047 in) ± 12 mm (0.472 in) 111 mm (4.370 in) ± 12 mm (0.472 in) 181 mm (7.125 in) ± 12 mm (0.472 in) Ride Height -- Rear Wheel Drive (RWD) Super Cab -- Heavy Payload Package -- (18" Wheels) Item 163-in wheelbase, 3.5L GTDI Front Rear 163-in wheelbase, 5.0L Front Rear Specification 129 mm (5.078 in) ± 12 mm (0.472 in) 181 mm (7.125 in) ± 12 mm (0.472 in) 129 mm (5.078 in) ± 12 mm (0.472 in) 182 mm (7.165 in) ± 12 mm (0.472 in) Ride Height -- Rear Wheel Drive (RWD) Crew Cab -- HEV Item 145-in wheelbase, 3.5L LD HEV Front Rear 157-in wheelbase, 3.5L LD HEV Front Rear 145-in wheelbase, 3.5L LD Limited HEV Front Rear Specification 120 mm (4.724 in) ± 12 mm (0.472 in) 165 mm (6.496 in) ± 12 mm (0.472 in) 122 mm (4.803 in) ± 12 mm (0.472 in) 167 mm (6.574 in) ± 12 mm (0.472 in) 112 mm (4.409 in) ± 12 mm (0.472 in) 162 mm (6.377 in) ± 12 mm (0.472 in) Ride Height -- Four-Wheel Drive (4WD) Crew Cab -- HEV Item 145-in wheelbase, 3.5L LD HEV Front Rear 157-in wheelbase, 3.5L LD HEV Front Rear 145-in wheelbase, 3.5L LD Limited HEV Front Specification 118 mm (4.645 in) ± 12 mm (0.472 in) 161 mm (6.338 in) ± 12 mm (0.472 in) 115 mm (4.527 in) ± 12 mm (0.472 in) 165 mm (6.417 in) ± 12 mm (0.472 in) 112 mm (4.409 in) ± 12 mm (0.472 in) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 1-14 Section 1: General Information General Information Ride Height -- Four-Wheel Drive (4WD) Crew Cab -- HEV (Continued) Rear Vehicle Lean (side-to-side height differences), All Vehicles Item Front -- maximum Rear -- maximum 161 mm (6.338 in) ± 12 mm (0.472 in) Specification 7 mm (0.276 in) 8 mm (0.315 in) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 SECTION 2: Electrical Table of Contents Contents PAGE Section 2: Electrical ...................................................................................................................................................................... 2-2 Electrical Basics ...................................................................................................................................................................... 2-2 Electrical Systems Management ............................................................................................................................................ 2-2 Generator Output .................................................................................................................................................................... 2-2 Charging Margins ................................................................................................................................................................... 2-2 Powertrain Control Module (PCM) -- Red Area ..................................................................................................................... 2-4 Disabling Brake Lights ............................................................................................................................................................ 2-4 Auxiliary Power Point (12V DC) .............................................................................................................................................. 2-4 Sealing Pass-Thru Points/Openings ....................................................................................................................................... 2-4 Sealing Option For Body Openings/Pass-Through Points ..................................................................................................... 2-5 Decommissioning ................................................................................................................................................................... 2-5 General Guidelines ................................................................................................................................................................. 2-6 Splices and Repairs .............................................................................................................................................................. 2-12 Electrical items for the F-150 Police Responder ................................................................................................................... 2-16 Brake Signal ......................................................................................................................................................................... 2-17 Battery Power Access Points ................................................................................................................................................ 2-17 Ignition Power (Run/Start) Signal ......................................................................................................................................... 2-20 Vehicle Speed Output ........................................................................................................................................................... 2-20 Driver Door Ajar .................................................................................................................................................................... 2-21 Delayed Accessory ............................................................................................................................................................... 2-22 Body Control Module (BCM) ................................................................................................................................................. 2-23 How To Change Option Content .......................................................................................................................................... 2-23 Rear Power Window Disable ................................................................................................................................................ 2-23 Wiring Reference Information ............................................................................................................................................... 2-23 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-2 Section 2: Electrical Electrical Section 2: Electrical Electrical Basics Inside a vehicle, electricity is supplied through powered, or hot, wires. This is 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 allows the electric current to flow through the hot wire to illuminate the light. Once the electricity has done its work, its potential drops to zero, just as water loses pressure after flowing through a sink or laundry tub. The electrical system uses ground wires to return the current to its source. Just as a plumbing system has drainpipes through which water runs into the sewer mains or the ground. The light or equipment powered by the current, technically called the load, can be compared to a water wheel that remains motionless until a stream of water causes it to turn. A load may be one of 2 kinds. The first consists of a resistance -- a material that permits the passage of electric current, but only with difficulty, and thereby creates heat. The tungsten filament of an incandescent bulb is resistance; so is the heating element of an electric heater of a coffee pot. A load may also be an inductance -- typically a motor with windings of copper wire, in which the magnetic fields generated by the current create motion. At any moment, the demand on an electrical system depends on the number of loads in operation and their consumption of energy, just as demand on a water system depends on how many faucets are opened and how wide they are opened. The mechanics and physical fittings of the system are simple. Current moves throughout the vehicle in wires of different sizes, according to the current a circuit may have to carry. Power is supplied directly to equipment through connectors. Electrical Terms VOLT is the unit of electrical potential, equal to the difference of electrical potential between 2 points on a circuit. AMPERE is the unit used to measure the amount of current - that is, the number of electrically charged particles called electrons - that flows past a given point on a circuit each second. It is similar to measuring the amount of water flowing through a pipe at any given point. The larger the pipe is, the more water that can flow past the point per second. Similarly, the bigger the wire is, the more current that can flow through it at any given point. Current that has lost its voltage still has amperage as it completes the circuit and returns to the battery. WATT is the unit of power. It indicates the rate at which a device converts electric current to another form of energy, either heat or motion, or to put it another way, the rate at which a device consumes energy. The relationship of volts, amperes and watts to one another is expressed in a simple equation that enables you to make any calculations you may need for correct and safe electrical modifications to the vehicle. Volts x amperes = watts. If the current is at 12 volts and a device requires 4 amperes of current, the equation will read 12 volts x 4 amperes = 48 watts. To figure the current needed for a device rated in watts, turn the equation around: watts/volts = amperes. For example, if you have a piece of equipment, such as a communications radio, that uses 120 watts: 120 watts/12 volts = 10 amperes. 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. Examine the proposed equipment for vehicle installation. Add up the current requirements. If the current requirements exceed what the vehicle can reasonably be expected to be able to provide, the battery will begin discharging to provide the power to the equipment that the generator is unable to provide. After some period of time, the vehicle will shut off as the battery voltage decreases to a level that cannot sustain vehicle operation. There are alternatives that can be considered to minimize system electrical overload. Consider the current requirements of equipment before it is purchased and installed. Modern light bars and radios use a fraction of the current than units made as recently as 1996. As the light bar is typically the most power intensive unit installed on most police vehicles, considerable attention should be given to its current requirements. Changes in officer habits while in the field can make a difference as well. When a vehicle is sitting at an accident scene and no one is in the car, the A/C can be turned off until the officer is ready to get back into the vehicle. The A/C is among the largest current users of non-police equipment. As such, it can impact available power for other uses as well. Generator Output The 240 amp generator used by the F-150 is controlled by the Powertrain Control Module (PCM). Charging Margins Generator output varies with engine speed and ambient temperature. The worst case for police vehicles is when the vehicle is idling for long periods of time on a very hot day. Lower engine speeds while idling, coupled with high underhood temperatures that may approach 93°C (200°F), combine to minimize power output from the generator. At the same time, electrical demand on the vehicle is often at its highest because the A/C loads are added to the usual electrical loads experienced in emergency situations. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-3 Section 2: Electrical Vehicle Component Electrical Loads Vehicle component electrical loads are shown in the table below. Not all features are powered all the time, so actual vehicle loads on the power supply system will vary. Component Base Miscellaneous base loads Cooling Cooling fan (increase high) 800W X 75% Climate Control A/C clutch A/C Fan-to-Face -- High Speed A/C Fan-to-Face -- M/H Speed Heater Fan-to-Foot -- M/H Speed Heater Fan -- Defrost -- High Speed Rear climate control Lighting Exterior and Instrument Panel Lamps (non-dimmable) Headlamps -- Low Beam Headlamps -- High Beam (incremental) Incandescent brake lights with CHMSL Heated Features Heated rear windows Other Radio Front wiper low speed Electric trailer brake Typical Vehicle Load = 140- 170 Amps Amps 19.6 43.4 3.3 21.3 17.2 12.2 16.9 56.8 3.2 8.9 9.9 10.7 21.4 6.0 4.0 8.0 Typical Police Equipment Loads for equipment commonly found on police vehicles are shown in the table below. Not all equipment will be operating at the same time, so actual loads on the power supply system will vary. Component Communications radio Mobile data transmitter Light bar Light bar with all internal accessory lights activated Spotlights (each) Alley lights (each) Radar Camcorder Amps 4.0 (8.0 with microphone active) 3.0 28-43 36-63 7.8 1.0 0.8 0.5 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-4 Section 2: Electrical Electrical Powertrain Control Module (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. Connecting any aftermarket electrical equipment into the brake light circuit or any other circuit connected to the PCM, anti-lock brake computer, air bag system or any other vehicle system will cause a vehicle malfunction. Disabling Brake Lights Do not disable the brake light circuits for any reason. For additional information, refer to Section 1: General Information in this guide. Auxiliary Power Point (12V DC) NOTICE: Do not plug optional accessories into the cigar lighter socket (if equipped). Incorrect use of the lighter/socket can cause damage not covered by the warranty. NOTICE: Power outlets are designed for accessory plugs only. Do not insert any other object in the power outlet as this will damage the outlet and blow the fuse. Do not hang any type of accessory or accessory bracket from the plug. Incorrect use of the power outlet can cause damage not covered by the warranty. The auxiliary power point is located on the instrument panel. Do not use the power point for operating the cigar lighter element (if equipped). To prevent blowing the fuse, do not use the power point(s) over the vehicle capacity of 12V DC/180W. If the power point or cigar lighter socket is not working, a fuse may have blown. To prevent the battery from being discharged, do not use the power point longer than necessary when the engine is not running. Always keep the power point caps closed when not being used. Sealing Pass-Thru Points/Openings Underbody · Any holes in the body must be sealed with Motorcraft® Seam Sealer (TA-2-B). · Any damaged parts must be replaced. Following are some examples: · spare tire tub · auxiliary A/C pass-through · air extractors (replace if damaged) · wiring grommets · body plugs · floor pan Examples of wiring pass-throughs that were sealed incorrectly and correctly Proper care and due diligence must be used on all openings at any location on the vehicle from the dash panel to the rear of the vehicle. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-5 Section 2: Electrical Dash Panel Any seals and/or holes in the dash panel must be replaced and/or properly sealed using Motorcraft® Seam Sealer (TA-2-b). Sealing Option For Body Openings/Pass-Through Points · Pass-through or other openings of similar size should be sealed using the recommended foil-backed mastic patch. · Foil-backed mastic patch should be used to cover and seal body openings. · Part number for foil-backed mastic patch: · Following are service part numbers for two different size foil-backed mastic patches: · 4L3Z18203A16AA; size of patch - 1.5 x 147 x 330mm · DA5Z65203A16A; size of patch - 1.5 x 100 x 300mm Decommissioning Vehicle Sealing of Aftermarket Equipment At the end of its useful life as a police vehicle, many vehicles are decommissioned having lights, wiring and other equipment removed and vehicles are sold for other uses such as retail applications. The openings remaining in the body/components are potential leak paths for exhaust gas into the cabin under certain conditions. These openings must be sealed prior to the vehicle going to auction or any other application. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-6 Section 2: Electrical Electrical When customized equipment has been removed from your vehicle, body panels and seals may be compromised. Thoroughly inspect your vehicle for any signs where the equipment has been removed, for example: holes and damage to body seals. Any openings should be sealed with a plug and a sealant. The opening can be modified to enable a plug to seat properly promoting a better sealing surface. The sheet metal surface with the opening should be treated to prevent corrosion prior to inserting the plug and sealant. Any items that remain on your vehicle must be inspected and any sign of damage repaired immediately. Failure to follow this instruction may result in water and exhaust fumes entering the passenger compartment. See your authorized ford dealer for more information and direction regarding proper sealing procedures. Common Ford Plug Part Number W716284S W714104S W711539S W651021S Hole Diameter 0.859 inches / 21.83 mm 1.07 inches / 27.25 mm 1.378 / 35.0 mm 1.683 inches / 42.75 mm Tools For Creating A Circular Opening Two suggestions for tools that can be used for creating and/or modifying an existing opening for a plug are a Knockout Punch or Step Bit. General Guidelines · Provide circuit protection (fuses) for all wiring. The fuse rating should not exceed either the rated wiring current capacity or the total current requirements for all the add-on components on the circuit. Install fuses as close to the point of tapped power as possible. · Document all revisions to the electrical system and place with the vehicle Owner's Literature. Color code and/or label all revisions or additions to wiring. · Provide protective covering in all areas that could be damaged during normal equipment installations. · Disconnect the negative battery cable of vehicles stored on-site to reduce the possibility of draining the battery by lights or other equipment. · Do not allow control panels attached to the instrument panel to protrude into the driver and passenger air bag deployment zones. For additional information, refer to Section 5: Reference Information in this guide. · Do not install switches and gauges in the driver or passenger knee impact areas. · Inspect all Ford gauges, lights and switches for correct operation after instrument panel work is performed. · Correctly secure all wiring relocated or removed while working behind the instrument panel to prevent chafing, squeaks and rattles. · Provide adequate retention for wiring harnesses so that they are clear of bolts, corners or edges which could abrade the wires during normal vehicle operation. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-7 Section 2: Electrical · Anticipate misrouted wiring situations and protect all wiring from penetration by screws and raw edges. See Wire Routing for further information. · Weather seal all exposed electrical connections exposed to the elements. · Do not use quick splice connectors or wire nuts. · Install the fuse panel so fuses are readily accessible. · Make sure that connections are easily accessible for assembly and service. · Make sure submersible connectors do not lose their seals under extreme assembly conditions such as bending wires 90 degrees immediately after the connector. · Whenever using connectors, use a socket (female) connector on the electrical source side and a plug (male) connector on the electrical load side to reduce the possibility of a short circuit when disconnected. · Supplemental restraint systems must remain intact as received from Ford Motor Company. Before modifications are done to the vehicle, the system must be disarmed by following the instructions provided in the current F-150 Workshop Manual. · Adherence to the above guidelines is not to be understood as approval by Ford Motor Company of any specific revisions or additions to the vehicle's original electrical system. Keep Alive Memory (KAM) Power The electronic engine and transmission control modules require battery power to be supplied at all times to maintain the KAM. Keep this in mind when installing load disconnect switches or solenoids. Equipment Grounding Guidelines · Factory ground locations are not to be removed for any reason. · Do not ground the body to the transmission or transmission crossmember. Ground accessories to the chassis or the vehicle battery. · Splicing into circuitry relating to the electronic engine and/or transmission control systems is not acceptable because of the adverse effect on the electronic system operation. · Protect exposed electrical connections. Wire Insulation · Polyvinyl Chloride (PVC), rated at 90°C (194°F), is the standard wire insulation that is acceptable for inside body use, but is not acceptable for underhood/underbody wiring. · Hypalon insulation should be used on links only (Ford Specification ESB-M1L54-A). · 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. Terminals and Connectors Connector Types · Submersible (sealed) -- A connector capable of being immersed in water. · Weather-resistant -- A connector that will retain its sealing and connection qualities while being exposed to adverse weather conditions. · Duraseal crimp -- A supplier trade name for a sealed wiring repair or splice. When a connection is not defined (typical situation -- harness-to-harness connectors), the following suggestions should be implemented: · Determine the connector type. If it will be located in a hostile environment, use a submersible (sealed) connector; if not, use an open connector. A hostile environment is defined as being exposed to water and/or salt accumulation and/or high temperatures (for example, underhood, exterior panels and footwells). Use in-line connectors with secondary locks to prevent the terminal from being pushed out. -- Do not use single wires smaller than 14-gauge in a 2-way or larger weather-resistant connector (the very large style), since the wire may break during disengagement. -- Use Hypalon, XLPE or Elexar insulation in submersible connectors to maintain sealing integrity. PVC is not acceptable because it cold flows and allows setting in a deformed pattern, therefore compromising the integrity of the seal. · 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. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-8 Section 2: Electrical Electrical -- Analyze circuit requirements (signal levels, current, voltage) to determine the correct plating material (such as gold). Use of non-plated terminals is not recommended. -- Do not use plugs to seal holes in micropin connector grommets. It is very easy to forget to insert them during manufacturing and ruin the seal. Use a grommet with only the necessary number of holes or use dummy wires at least 600 mm (24 in) long. -- Fully align connectors prior to terminal connection -- terminal cavities should have minimum tolerance to prevent terminals from floating, bending or pin push-out during mating/engagement. -- Make sure connectors of similar type and color can be identified by operator to eliminate crossed connections and minimize assembly time. Avoid using similar types and colors of connectors close together. -- Be sure that connectors have positive locking devices that allow easy installation with a low insertion force and easy removal. The connector snap should be easily felt and heard. -- Eliminate the use of edgeboard, tang-type and molded-over connectors. The use of blade-type weather-resistant connectors is restricted to high-current applications which cannot be handled by submersible connectors. Circuit Protection and Electrical Load · Modification to existing vehicle wiring should be done only with caution and careful consideration of effects on the completed vehicle electrical system. Anticipated circuitry should be studied to determine the required circuit protection and to avoid feedback loops. · Added circuitry must be protected either by a base vehicle fuse or circuit breaker, or by a similar device supplied by the modifier. · When adding loads to a base vehicle-protected circuit, make sure that the total electrical load through the base vehicle fuse or circuit breaker is less than the device's load rating. · Use 80% of the fuse rating to determine maximum steady state load to reduce nuisance fuse failures. · 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. -- Never increase the rating of a factory installed fuse or circuit breaker. -- If the total electrical load including additional electrical components on any circuit, is less than the fuse protection rating or the capacity of some limiting component (switch, relay), the items to be added can be connected directly to that circuit. The headlamp switch circuits should never have additional lighting or electrical components directly connected. -- Added devices that exceed the current capabilities of the factory-installed system are best controlled through the use of a relay or separate switch. The coil of the relay can be fed from the circuit in the factory harness (now acting as a signal circuit) with added wiring providing feeds to the added electrical device. The relay selection is important and depends on current requirements, number of cycles expected in the relay lifetime, whether the relay is to be operated intermittently or for long periods of time and whether the relay is exposed to weather conditions or is installed in a protected area. When the current requirements of a circuit exceed the capacity of an available relay, the load should be reduced or divided through the use of additional relays. Wire Protection Requirements General Notes · Anticipate problems and design accordingly. Try to anticipate what could go wrong and modify your designs to address any adverse impact. · Review all connector applications and electrical systems to determine the need for solder, grease, weather-resistant or sealed connectors. Make sure components and wire insulation are compatible with greased connectors (important for long-term durability). · Make sure that drip loops or other means are provided to prevent water leakage into the vehicle through wiring assemblies that pass through the dash panel. · Use greased or sealed connectors in floor pan troughs which are subject to moisture coming through the carpeting. · Use XLPE insulation for uncovered runs that exceed 305 mm (12 in). Electrical Protection · Correctly route wires away from noise-generating wires or components. However, if routing near noisy wires or plugging into noisy components is unavoidable, additional protection must be designed into the harness. · Shielding -- Electro Magnetic Interference (EMI) -- Consider shielding if you must route close to high-current or noisy circuits. Use shielded wire and ground one side. Seal all splices in wire assemblies that use bare coaxial shielding (braid or tape) for EMI suppression, and insulate or tape over all shielding ends that terminate near any open connectors. This prevents splice and terminal shorts to the shielding. Minimize the length of conductors which extend beyond the shield. Failure to do this reduces the effectiveness of the shield. · Spike suppression, in general, is accomplished by connecting a diode or resistor-diode combination across the terminals of the noisy component. The diode should be sufficiently close to the component (both electrically and physically) so that inductive spikes are clamped off. Make sure the diode is connected with the correct polarity. Correct routing and retention will reduce the likelihood of chafing or pinching. When this ideal routing is unattainable, the following additional protection is needed: 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-9 Section 2: Electrical Mechanical/Environmental Protection · 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. -- Polyken 267 is a substitute tape that may be used in lower temperature areas of the engine compartment (apron area). · Convolute - Use convolute for all underhood/underbody applications or when increased temperature, abrasion or pinch resistance is required. Convoluted tubing comes in different diameters and materials to accommodate different temperature ranges and harness sizes. -- Use polyethylene convolute when abrasion is the only consideration; this convolute is adequate up to 96°C (205°F) maximum. Use nylon convolute when underhood/underbody or abrasion and temperature are considerations; nylon convolute is adequate up to 177°C (350°F) maximum. -- On all engine-mounted wiring or bend points, use vinyl tape on the outside of the convolute to prevent wiring from looping out. This tape must be able to withstand temperatures 135°C (275°F) or higher. -- Tape convolute junctions with abrasion-resistant tape (Polyken 267, fiberglass). · 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. There are other means of protection available that are not listed. Grommets and Sealing Requirements Any additional wiring routed through sheet metal must pass through a grommet that both seals the opening and locates the wire(s). Two-piece grommets (rubber with plastic inserts) are recommended to facilitate installation and retention. · Locate grommets so they are accessible for correct seating (achieved by pulling) in sheet metal holes. · Ramp grommets at the insertion end to facilitate installation and sealing. · Be sure the direction of the hole punch is in the direction of grommet seating and the hole is burr-free. · Make sure the grommet molding compound will adhere to the harness to prevent slippage. · Make sure the grommet will withstand the environment (temperature, splash). · Be sure that holes are large enough to allow the harness to be installed without causing circuit damage. · Use adhesive tape on main trunks or branches with at least a 50% overlap to prevent wicking through grommets. Be certain to diaper- wrap the takeouts. Wire Routing WARNING: Do not place electrical component attachments or ground screws adjacent to vehicle fuel tanks, fuel filler pipes, fuel lines, fuel vapor lines or carbon canisters. Failure to follow these instructions may result in personal injury in the event of a collision. Wire harness routing should conform to the following: · Protect wires routed through holes in sheet metal or castings with a grommet whether or not conduit is used (see figure below). 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-10 Section 2: Electrical 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). · Route wires to provide at least 76 mm (3 in) of clearance to moving parts in their extreme movement location, unless positively fastened and protected by a conduit. · Avoid wire routing without conduit in areas where temperatures exceed 82°C (180°F). Maintain a minimum clearance of 152 mm (6 in) from exhaust system components. Heat insulation and heat shields must be used on the wires routed in high temperature areas. · Make certain all underhood or underbody wiring is cross-linked polyethylene high temperature insulation wire with a 135°C (275°F) minimum rating, consistent with SAE specification J1128 Type SXL wire. Do not use normal PVC wire in underhood or underbody applications. · Make sure all ground locations are readily accessible for installation, service and verification. · Do not place ground attachments in high-splash areas. · Do not route underbody wiring over the exhaust system. · Route the underhood/underbody wiring in conduit for protection. Minimum conduit rating is 177°C (350°F). 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 rattles. · When wiring is routed between 2 members where relative motion can occur, secure the wiring to each member with enough wire slack to allow flexing without damaging the wire. · Wiring exposed to weather must provide a drip loop to prevent moisture from being conducted into the device through the wire connection (see figure below). 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-11 Section 2: Electrical · Avoid routing wires into areas exposed to wheel splash. When such routing cannot be avoided, adequate clipping and/or protective shields are required to protect the wires from stone and ice damage. Allow adequate slack in wiring between the engine and stationary components to compensate for engine roll. · Avoid routing wires under the frame side members or at points lower than the bottom frame flange. · Use plastic cable ties for bundling only (securing to other wires). · 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 additional wiring or tubing are routed through sheet metal panels, new holes with correct wire protection and sealing must be used. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-12 Section 2: Electrical 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. · Do not use pointed screws for attachments. Also check that screws used in the vicinity of the wiring are blunt-ended. · To minimize the potential for wiring shorts, do not use drill point screws. Trim components (including wiring shields) should use pin-type attachments instead of screws. · Always check areas that screws protrude into for verification that an interference condition to other components does not exist. · Make sure that retainers used are capable of withstanding the environment over the vehicle's life expectancy. 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. · Strip wire ends making sure that individual conductor strands are not damaged. · When soldering, make sure an adequate mechanical joint exists before applying solder. Use only resin-core solder. Acid-core solder should not be used since it may result in corrosion. · For crimp joints, use butt-type metal barrel fasteners and the correct tool at the appropriate setting for the wire size (such as Motorcraft® Crimp Tool S-9796) specifically designed for this type of work. · Make sure splice joints are adequately sealed and insulated. In an outside environment, use Duraseal butt connectors or equivalent. A durable substitute splice joint can be achieved by using a bare metal barrel, crimping, flow-soldering and covering with shrink tubing. Quality electrical tape can be used inside the vehicle, but is not recommended for an outside environment. · Be sure the new wire is not a lesser gauge than its original mating wire. Recommended Splicing Method -- Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect the battery ground cable. 2. Strip wires to appropriate length. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-13 Section 2: Electrical 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. 7. NOTE: Overlap tubing on both wires. Evenly position heat shrink tubing over wire repair. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-14 Section 2: Electrical Electrical 8. Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 9. Reconnect the battery ground cable. Sealed Connectors Ford Part Number E6FZ-14488-A E6FZ-14488-B E6FZ-14488-C Part Name Butt Connector Gauge: 18-22, Color: Red Butt Connector Gauge: 14-16, Color: Blue Butt Connector Gauge: 10-12, Color: Yellow Class C C C 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. If the splice is extremely unbalanced (more circuits on one side than the other), heat shrink insulation will not provide a correct seal. Evaluate the use of double terminals instead of splices where practical in these situations. Recommended Splicing Method -- Crimp (For 1022 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect the battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-15 Section 2: Electrical 4. Select the appropriate wire splice 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. (1) Cavity (2) Indenter 6. Crimp the connector. (1) Center one end of the wire splice in the appropriate crimping chamber. (2) Insert stripped wire into the barrel. (3) Holding the wire in place, squeeze the tool handles until ratchet releases. 7. Repeating Step 6, crimp the other half of the splice. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-16 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. Electrical 9. Evenly position supplied heat shrink tubing over wire repair. 10. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 11. Reconnect the battery ground cable. Electrical items for the F-150 Police Responder · Location on dash panel to pass power through from the battery to police equipment in the cab/bed. · Park signal, pin number, wire color. · Brake signal, pin number, wire color. · Battery power access point and fuse rating, pin number, wire color. · Ignition power access point and fuse rating. · Vehicle speed output. · Driver door ajar signal. · Start fuse number/location (i.e Battery Junction box (BJB)), wire color. · Accessory delay fuse number/rating, location , wire color. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-17 Section 2: Electrical Brake Signal · Connector C1, Pin 1. · Connector is located at BCM J1 at the passenger side outboard footwell. · Wire color is Grey/Orange (GY/OG). · Circuit is closed 12 volts when brake is depressed. NOTE: Use as a "sense"ONLY, should not be used to drive a relay. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-18 Section 2: Electrical Battery Power Access Points · Located under the second row passenger seat on the floor of the vehicle. · B+ power lug is inside the red enclosure. · Typically fused to 80 amps. · Police responder ONLY, not found on hybrid SSV. Electrical 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-19 Section 2: Electrical 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-20 Section 2: Electrical Ignition Power (Run/Start) Signal Electrical · Run/Start signal is available via pin 23 of the 36 pin connector C3 located at BCM J3 at the passenger outboard footwell. · The circuit/terminal is not populated and will need to be added. Fuse 22 is rated at 5A. Vehicle Speed Output 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-21 Section 2: Electrical · Vehicle speed is recorded and sent to the Antilock Brake System (ABS) module for each wheel. · The vehicle speed (Speedometer) reading wold be communicated via CAN messaging over the high speed 2 network or through the CAN message gateway. Driver Door Ajar · Driver door ajar signal is available via pin 33 of the 52 pin connector C5 of the BCM J5 (located at the outboard passenger foot-well). · Wire is Green/Violet GN/VT. NOTE: Use as a "sense"ONLY, should not be used to drive a relay. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 2-22 Delayed Accessory Section 2: Electrical Electrical · Delayed accessory fuses located in BCM J1 at the passenger outboard footwell. · Fuse 02, 10A pin 2 on BCM C1 connector brown/yellow BN/YE drives driver window switches sliding backglass, inverter and moonroof. NOTE: This fuse is shared with already populated pin 30. Adding additional loads increase the risk of blowing a fuse. Police Radio Speaker Outputs Front Speakers 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Electrical 2-23 Section 2: Electrical Rear Speakers · Left Front speaker positive and negative circuits are available in the 30 pin connector located by the drivers outboard footwell at pins 29 and 30 wire color white/brown (WH/BN). · Right Front speaker positive and negative circuits are available in the 30 pin connector located by the passengers outboard footwell at pins 26 and 25wire color white/orange (WH/OG). · Left Rear and Right Rear speakers positive and negative circuits are available in the 30 pin connector located between the front seats under the center floor console at pins 29/30 and 26/25 wire color white/green (WH/GN) brown yellow (BN/YE) brown/white (BN/WH) Brown Blue (BN/BU). · Center speaker positive and negative circuits are available in the 2 pin connector located at the center speaker top of the instrument panel wire color green (GN) and gray/yellow (GY/YE). Body Control Module (BCM) How To Change Option Content Courtesy Lamp Disable (Dark Mode) Move the panel dimmer control to the full down position, past the detent, to prevent the interior lights from illuminating when the doors are opened. Rear Power Window Disable The rear power windows of the F-150 Police Responder can be disabled by disconnecting the rear window motor connectors. These connectors are located inside the door, behind the door trim panel and must be secured to prevent interference with the window mechanisms. While they are disabled, the master window control switch will not control the rear windows. Refer to F150 Wiring Diagrams Manual for additional power window wiring information. Wiring Reference Information Ordering Information To obtain information about ordering complete copies of Ford or Lincoln/Mercury publications, call 1-800-782-4356. 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. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 SECTION 3: Installation Considerations Table of Contents Contents PAGE Section 3: Installation Considerations ........................................................................................................................................... 3-2 Mobile Radio Installation Guidelines ...................................................................................................................................... 3-2 Push Bumpers ........................................................................................................................................................................ 3-3 Siren and Grille Lights ............................................................................................................................................................ 3-4 Interior Equipment Mounting ................................................................................................................................................... 3-4 Partition Installation Guidelines .............................................................................................................................................. 3-4 Vehicle Design and Component Location .............................................................................................................................. 3-4 Battery Saver .......................................................................................................................................................................... 3-6 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 3-2 Installation Considerations Section 3: Installation Considerations 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 engineering principles and generally accepted practices, using the best information available at the time of publication. These guidelines are intended to supplement, but not to be used in place of detailed instructions for such installations which are the sole responsibility of the manufacturer of the land mobile radio. Since it is not possible to cover all possible installations of 2-way radio equipment, Ford Motor Company cannot be held responsible for incidental or consequential damages arising from the use of the information contained herein. Certain land mobile radios or the way in which they are installed may affect the vehicle operations such as the performance of the engine and driver information, entertainment and electrical charging systems. Expenses incurred to protect the vehicle systems from any adverse effect of any such installation are not the responsibility of Ford Motor Company. General Information Ford Motor Company vehicles are designed and tested for safe operation with correctly installed and used land mobile/amateur radio communication equipment with up to 100 watt transmitter power. Special design considerations are incorporated into all Ford vehicle electronic systems to provide immunity to radio frequency signals. To maintain compatibility with vehicle electronic systems, mobile 2-way radio and telephone equipment must be installed correctly by trained personnel, observing these general guidelines: · Power connections should be made directly to the battery and fused as close to the battery as possible. Avoid using cigar lighter or power point receptacles as power sources for radio communication equipment. · Antennas for 2-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases, since magnets may affect the accuracy or operation of the compass on vehicles, if so equipped. · The antenna cable should be high quality, fully shielded coaxial cable, and kept as short as practical. Avoid routing the antenna cable in parallel with vehicle wiring over long distances. · Carefully match the antenna and cable to the radio to achieve a low Standing Wave Ratio (SWR) and to avoid radio frequency currents on the antenna cable shield. Check installations for possible interference between the communications equipment and vehicle electronics. Mobile radio equipment with greater than 100 watts output may require special precautionary measures beyond those outlined in this document. This Guide is a supplement to the radio manufacturer's installation instructions for installing communication equipment in Ford vehicles. Additional sources of information are listed on page 3-4. Radio transmitters are regulated by the Federal Communications Commission (FCC) in the United States. Compliance with FCC regulations is the responsibility of the manufacturer and/or user of transmitter equipment and not Ford Motor Company. Installation Guidelines WARNING: Do not mount any transceiver, microphones, speakers or any other item in the deployment path of the airbag system. Failure to follow these instructions may result in personal injury. Transceiver Location Select a transceiver location that provides a solid mounting point, does not interfere with the vehicle operator controls and provides adequate ventilation. Before using screws to mount the transceiver equipment, be sure to check for vehicle wiring under the carpet or behind the instrument panel which could be pinched, cut or otherwise damaged. Radio Wiring and Routing Make transceiver power connections directly to the battery and appropriately fused as close to the battery as possible. A weatherproof fuse holder is recommended. Twist the positive and negative power leads together to enhance noise immunity. Use caution when routing wires between the passenger and engine compartments to avoid chafing or pinching of wires. Use grommets over any exposed sharp edges and strain reliefs to keep wires in place. Seal all holes to prevent moisture intrusion. Route and secure all underhood wiring away from mechanical hazards such as exhaust manifolds steering shaft, throttle linkage, and fans. Maintain as much distance as possible between mobile radio power leads and the vehicle's electronic modules and wiring. Avoid running power leads in parallel with vehicle wiring over long distances. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Installation Considerations 3-3 Section 3: Installation Considerations 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. Antenna Location and Installation Permanently installed antennas are preferable over magnetic, glass or body lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas can reflect significant power back at the feedpoint; this reflected power could then radiate from the feedline inside the passenger compartment and be picked up by the vehicle wiring. However, a magnetic-mount antenna is a good tool for checking the proposed fixed antenna location for unwanted effects on the vehicle since antenna location is a major factor in these effects. Glass-mounted antennas should be kept as high as possible in the center of the rear window or windshield. 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. If a magnetic mount antenna is used, take care to locate the magnetic base in a location which avoids interference to the vehicle's compass mechanism, if so equipped. Also, some Ford vehicles use non-metallic body panels (decklids, etc.). If metallic backing panels are used, do not block the reception paths for factory installed antennas, such as Global Position Satellite (GPS) transceivers, if so equipped. NOTE: To maintain proper operation, periodically check the antenna installation for correct SWR and any signs of damage or deterioration. Antenna Tuning: It is important the antenna be tuned correctly and reflected power be kept to less than 10% (VSWR less than 2:1). Antenna Cable Routing Always use a high-quality, 1-piece coaxial cable (at least 95% shield coverage). Connector quality and termination techniques are just as important. The ARRL handbook provides excellent guidelines for terminating coaxial cables. Treat antenna cable in the same way as the control and power cables. Avoid sharp edges and pinches and keep the cable as short as possible. Also, avoid routing the antenna cable in parallel with vehicle wiring over long distances it is necessary to cross over wiring cross at right angles. In some cases, additional shielding between the antenna cable and the vehicle wiring may be helpful. Additional Information Troubleshooting Should vehicle-radio interaction develop following installation, the source of the problem should be identified prior to further operation of the vehicle. Most interaction problems can be eliminated by following these installation guidelines. Possible causes of vehicle-radio interaction include: · Antenna location (move antenna to another position) · Antenna feed line routing (locate as far as possible from vehicle electronics and wiring) · Inadequate shielding or loose/corroded connectors associated with the antenna feed line · Mismatched antenna or high SWR · Power feeds not connected directly to the vehicle battery · Power feed routing (locate as far as possible from vehicle electronics and wiring) 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. Newington, Connecticut 06111-1494, Phone 203-666-1541 / Fax 203-665-7531 Giving 2-Way Radio Its Voice (booklet) Champion Spark Plug Company, Automotive Technical Services Dept., P.O. Box 910, Toledo, Ohio 43661 Push Bumpers Effect On Air Bag Deployment Different push bumper designs have different deformation characteristics in a crash situation that may or may not affect the deployment of air bags. Without the benefit of crash tests on vehicles equipped with 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. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 3-4 Installation Considerations Section 3: Installation Considerations Effect On Weight Distribution The balance and weight distribution of a vehicle is carefully planned to achieve optimal stability and handling. Push bumpers can change this weight distribution by adding excessive weight to the front of the vehicle. There are many different styles of push bumpers available. Depending on the mounting and weight of the push bumper to be installed, it could have an adverse effect on the handling of a vehicle. Always verify the vehicle ride height after the adding a push bumper. For additional information, refer to Section 1: General Information in this guide. Adjust the ride height if the measurements are not within specifications. Airflow The engine cooling system on a vehicle relies on correct airflow through the radiator to keep the engine at its correct operating temperature. When adding a push bumper to a vehicle, make sure this airflow is not obstructed, especially when lights and sirens are mounted on the push bumper. Reduced airflow could put additional strain on the cooling system and shorten the operational life of related components. During the installation process, keep the placement of components away from the grille area of the vehicle. 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. Reduced airflow could put additional strain on the cooling system and shorten the operational life of related components. During the installation process, keep the placement of components away from the grille area of the vehicle. Interior Equipment Mounting Mounting of equipment should be accomplished by attaching to sheet metal or other structural points that will maintain its integrity during an impact and/or useful life during police use. WARNING: Interior trim panels should not be used for mounting police equipment. Partition Installation Guidelines WARNING: Side curtain deployment drawing are shown in Section 5: Reference Information. Review the deployment drawings before installing a partition or other equipment to make sure that there is no deployment interference. Failure to follow these instructions may result in personal injury. WARNING: The partition and the installation hardware of the partition must not interfere with the correct operation of the safety belt, safety belt retractor, side impact sensor and the safety belt height adjusters. Failure to follow these instructions may result in personal injury. WARNING: Installation of prisoner partitions may increase the risk of injury to front seat occupants if the vehicle is impacted from a high-speed rear-end collision. This risk should be balanced by the law enforcement agency against the risk of injury to the officer associated with prisoner transportation. Failure to follow these instructions may result in personal injury. Vehicle Design and Component Location Restraint system component location, airbag location and airbag deployment drawings are provided in Section 5: Reference Information. Consult the drawings before equipment is installed inside the passenger compartment to make sure that the mounted equipment does not interfere with restraint and/or airbag deployment. Safety Belt Retractor and Side Impact Sensor 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. Removing slack from the safety belt helps to correctly position the occupant and allows for maximum effectiveness of the safety belts and the air bags. · Do not use the safety belt retractor bolts for mounting the partition. · Do not mount any partition hardware on the B-pillar. · Do not mount any partition hardware that will interfere with the correct sealing of the door. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Installation Considerations 3-5 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. Failure to follow this instruction may cause personal injury. Restraints Control Module (RCM) WARNING: Do not relocate the Restraints Control Module (RCM) or modify its installation in any way. Failure to follow these instructions may result in personal injury. The RCM is mounted on the center tunnel under the carpet (under the first row bench seat if equipped). The RCM orientation is critical for correct operation of the restraint systems. Do not use the RCM mounting bolts as attachment points for equipment. Air Bag Deployment Interference WARNING: Side curtain deployment drawing are shown in Section 5: Reference Information. Review the deployment drawings before installing a partition or other equipment to make sure that there is no deployment interference. Failure to follow these instructions may result in personal injury. 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. Dash, tunnel or consolemounted equipment should not be placed outside of the specified zone. Failure to follow these instructions may result in personal injury. WARNING: Do not mount equipment between the side of the front seat and the door trim that would block deployment of the side air bag. Failure to follow these instructions may result in personal injury. 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. Do not mount or place any objects in the deployment path of an air bag. Air bags must be allowed to fully deploy without restriction. The deployment of air bags is not compatible with any configuration of police equipment mounting that places objects in the air bag deployment path. Equipment mounted or placed in the deployment area of an air bag will reduce the effectiveness of the air bag, damage the air bag and potentially damage or dislodge the equipment. Seat Bolts NOTICE: Do not install longer seat bolts if reinstalling seats. The vehicle safety belts and seat assemblies are factory installed in their correct location. Seat attaching bolts are not to be used as attachment points for any equipment. Any added material between the seat bolt and the seat frame could have unpredictable effects on the seat bolt torque. If the safety belts are removed for any reason, all of the appropriate attaching hardware must be hand started and then tightened to the correct torque specifications as per the workshop manual. Correct operation must be verified before returning the vehicle to service. NOTE: Work Shop manual should be reviewed for seat bolt replacement direction when seat(s) are removed and replaced/reinstalled. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 3-6 Installation Considerations Section 3: Installation Considerations Driveshaft Clearance When installing police equipment such as a console or other equipment in the console area, it is important to consider the available clearance between the underbody and the driveshaft. Never use self-tapping screws and never use screws that are longer than necessary in the console area. Brake Line Clearance 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. Battery Saver NOTE: Time-out is 10 seconds if the vehicle is in factory mode or 1 minute if the vehicle is in transport mode. NOTE: The battery saver does not control the parking lamps if the headlamp switch is in the PARKING LAMPS ON position The BCM provides automatic shut-off of the courtesy and demand lamps after a time-out period when the ignition is OFF. A timer in the BCM starts when: · the ignition transitions to OFF. · the front or rear interior lamp was switched ON. · any door becomes ajar. · any button of a remote keyless entry (RKE) transmitter is pressed. · a door is unlocked using the passive entry feature. · a valid code was entered on the keyless entry keypad. When 10 minutes (30 minutes for demand lamps) have elapsed, the BCM automatically shuts off voltage to the lamps. The timer restarts (voltage is restored if the BCM is in battery saver mode) when: · the ignition transitions out of OFF. · the front or rear interior lamp was switched ON. · any door becomes ajar. · any button of the RKE transmitter is pressed. · a door is unlocked using the passive entry feature. · a valid code was entered on the keyless entry keypad. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 SECTION 4: Cargo Mounting Considerations Table of Contents Contents PAGE Section 4: Cargo Mounting Considerations .................................................................................................................................. 4-2 Cargo Area Equipment Mounting Guide ................................................................................................................................. 4-2 Cargo Loading ........................................................................................................................................................................ 4-2 Cargo Area Weight ................................................................................................................................................................. 4-3 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 © Copyright Ford 2021 FoMoCo 4-2 Cargo Mounting Considerations Section 4: 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. NOTICE: Inspect behind trim and under the vehicle when determining mounting locations. Be sure the drill/fasteners will not puncture/touch and will leave adequate clearance from the fuel tank, fuel lines, brake lines, wiring harnesses, evaporative emissions (EVAP) canister and the fuel pump shut-off switch as well as other vehicle systems. Refer to Section 5: Reference Information in this guide for additional illustrations showing the location of the fuel tank, fuel lines, brake lines and the fuel pump shut-off switch. Damage to vehicle components may occur. Be aware of the following component locations when mounting equipment in the cargo area: · Fuel tank · Fuel lines · Brake lines · Evaporative emissions (EVAP) canister · Electronic modules · Wiring harnesses · Spare tire 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. Failure to follow these instructions may result in personal injury. A acronym has been developed to increase police agency awareness of the importance of cargo packing. Improve police officer safety by implementing a cargo-packing process called "LOAD SAFE". Lateral Orientation And Direction LOAD Soft And Fixed Equipment SAFE 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 © Copyright Ford 2021 FoMoCo Cargo Mounting Considerations 4-3 Section 4: Cargo Mounting Considerations Equipment Categories and Placement WARNING: Gasoline should not be stored in the cargo area at any time, regardless of container. Failure to follow this instruction may result in personal injury. It is recognized that a wide variety of equipment is carried in police vehicles as noted above. This section addresses the inherent risks of various types of equipment in the event of a high-speed rear impact. · Carrying Not Recommended --The following items have been observed in police vehicles and should not be transported in the vehicle cargo area: containers with gasoline, loose ammunition, loose flares, loose fire extinguisher(s), loose 4-point lug wrenches, loose crowbars, loose axes and other loose equipment with potential injury capability in collisions. · Carry With Caution --These items will require special packing or mounting consideration. Examples include (with proposed orientation): fire extinguisher (fixed), lug wrench 4-point (fixed, vertical), rolotape measuring wheel (fixed, vertical), safety flares (lateral orientation, in a container), stop stick (lateral), shovel (lateral, place at rear of cargo area), shotgun and rifle (lateral, store in case), baton (lateral, place at rear of cargo area), electronic equipment and ammunition (container). Flares should be placed in a protective storage container (preferably soft-sided plastic). Flares with spikes attached should be laterally oriented in the cargo area. · 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, soft helmets and jumper cables. Cargo Area Weight The vehicle's high-speed handling and curb height becomes increasingly affected as weight is added to the cargo area. The more weight that is placed in the cargo area, the more it changes the ride and handling characteristics of the vehicle. Consider these factors when installing equipment and placing items in the cargo area of the vehicle. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 © Copyright Ford 2021 FoMoCo SECTION 5: Reference Information Table of Contents Contents PAGE Section 5: Reference Information ................................................................................................................................................. 5-2 Supplemental Restraint System (SRS) Component Location ................................................................................................ 5-2 Engineering Drawings ............................................................................................................................................................. 5-4 Exhaust System .................................................................................................................................................................... 5-11 2022 SSV HEV ONLY .......................................................................................................................................................... 5-13 Roof Bow Highlighted For Light Bar Installation ................................................................................................................... 5-14 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 5-2 Section 5: Reference Information Section 5: Reference Information Supplemental Restraint System (SRS) Component Location Reference Information Item Description 1 LH and RH front impact severity sensors 2 BECMB 3 FCIM (includes PAD indicator) 4 Passenger front door side impact sensor 5 OCSM (includes OCS sensor and gel-filled bladder) 6 Clockspring 7 Seat position sensors 8 Driver front door side impact sensor 9 RCM 10 LH and RH B-pillar side impact sensors (SuperCab) / LH and RH C-pillar side impact sensors (SuperCrew) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Reference Information 5-3 Section 5: Reference Information Item 1 2 3 4 5 6 7 Description RH side air curtain Driver airbag LH side air curtain Deployable steering column Passenger side airbag Driver side airbag Passenger airbag (includes canister vent) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 5-4 Reference Information Section 5: Reference Information Item 1 2 3 4 5 6 7 8 9 10 Description Front passenger seatbelt retractor (includes retractor pretensioner and anchor pretensioner) (SuperCrew shown, other body styles similar) RH rear outer seatbelt lower retractor (SuperCrew only, if equipped with inflatable seatbelts) RH rear outer seatbelt upper retractor (SuperCrew only, if equipped with inflatable seatbelts) RH rear outer seatbelt buckle assembly (SuperCrew only, if equipped with inflatable seatbelts) (includes seatbelt buckle, buckle switch and seatbelt inflator) Driver seatbelt buckle (includes buckle switch) Front passenger seatbelt buckle (includes buckle switch) Driver seatbelt retractor (includes retractor pretensioner and anchor pretensioner) (SuperCrew shown, other body styles similar) LH rear outer seatbelt lower retractor (SuperCrew only, if equipped with inflatable seatbelts) LH rear outer seatbelt upper retractor (SuperCrew only, if equipped with inflatable seatbelts) (includes seatbelt buckle, buckle switch and seatbelt inflator) LH rear outer seatbelt buckle assembly (SuperCrew only, if equipped with inflatable seatbelts) (includes seatbelt buckle, buckle switch and seatbelt inflator) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Reference Information 5-5 Section 5: Reference Information Engineering Drawings Airbag Deployment Interference WARNING: Do not place objects or mount equipment in front of the airbag module cover or in front seat areas that may come in contact with a deploying airbag, dash, tunnel or console-mounted equipment should be placed within the specified zone. Failure to follow these instructions may result in personal injury. WARNING: Dash, tunnel or console-mounted equipment should not be placed outside of the specified zone. Failure to follow these instructions may result in personal injury. WARNING: Do not mount equipment between the side of the front seat to the door trim that would block deployment of the side airbag. Failure to follow these instructions may result in personal injury. Driver/passenger airbags affect the way equipment can be mounted in vehicles. Any surfaces that could come into contact with an airbag during deployment must not damage the airbag or alter its deployment path. Sharp edges, corners or protrusions could damage the nylon airbag material and reduce the effectiveness of the airbag. Do not mount or place any objects in the deployment path of an airbag. airbags must be allowed to fully deploy without restriction. The deployment of airbags is not compatible with any configuration of police equipment mounting that places objects in the airbag deployment path. Equipment mounted or placed in the deployment area of an airbag will reduce the effectiveness of the airbag, damage the airbag and potentially damage or dislodge the equipment. Some approximate dimensions for airbags, at full inflation, are provided in Figures 1 through 4. These dimensions are somewhat flexible and represent free-form deployments without the loading of occupants. All airbag and equipment mounting zone dimensions are approximate due to different airbag deployment characteristics. Mount no equipment between the side of the front seat and the door trim that would block deployment of the side airbag. Item 1 2 3 Description From the center of steering wheel emblem. 14 inches (356 mm) From the center of the passenger airbag door. 14.2 inches (361 mm) No objects should be placed between the airbags due to airbag variability. 30.5 inches (775 mm) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 5-6 Reference Information Section 5: Reference Information Item 1 Description 39.9 inches (1014 mm) Item 1 2 Description Front passenger airbag 37.5 inches (953 mm) Front driver 18 inches (458 mm) Item 1 2 Description From the outboard side of seat 6.02 inches (153 mm) Forward of seat back 14 inches (356 mm) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Reference Information 5-7 Section 5: Reference Information Item 3 Description 39.9 inches (1014 mm) Item 1 2 3 4 Description Area on top of instrument panel. Equipment must not interfere with the drivers visibility. Airbag door must be kept clear for deployment of airbag. Area in front of electronic finish panel from the bottom of the ashtray to the top of the instrument panel Passenger Side. Area in front of electronic finish panel from the bottom of the ashtray to the top of the instrument panel Drivers Side. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 5-8 Reference Information Section 5: Reference Information Item 1 2 3 4 5 6 7 8 9 10 Description Area on top of instrument panel Area in front of center console from tunnel to instrument panel Prisoner screen 11 inches (279 mm) Area on tunnel between seats Height: 9.5 inches (241 mm) 13 inches (330 mm) Area on tunnel beneath center console Tunnel Depth: 2.5 inches (64 mm) Item 1 2 3 Description Area on top of instrument panel. Equipment must not interfere with driver visibility Area on tunnel between seats 10 inches (305 mm) 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Reference Information 5-9 Section 5: Reference Information Do not place any objects between the airbags due to airbag variability. 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. Failure to follow these instructions may result in personal injury. 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. The curtain airbag extends from the A-pillar to the C-pillar and from the roof rail to the beltline. · Do not mount equipment to the B, and C-pillars above the beltline. · Do not mount equipment to the A-pillar above the beltline except for spotlights. · Do not mount equipment on the headliner within 200 mm (8 in) of the side edges. · Do not mount equipment above the beltline within 200 mm (8 in) of the side glass from the A-pillar leading edge to the rear edge of the C- pillar. · Do not mount equipment on the headliner along the saddleries. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 5-10 Section 5: Reference Information Fuel System Top View Silhouette of Fuel System components Reference Information Fuel Pump (FP) Shut-Off Feature In the event of a moderate to severe collision, the vehicle is equipped with a FP shut-off feature that is initiated by the event notification signal. The event notification signal is a signal provided by the Restraints Control Module (RCM) to the FP control module. Signal communication between the RCM and the FP control module allows the PCM to shut off the FP. Should the vehicle shut off after a collision due to this feature, the vehicle may be restarted by first turning the ignition to the OFF position and then turn the ignition to the ON position. In some instances the vehicle may not start the first time and may take one additional ignition cycle. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Reference Information 5-11 Section 5: Reference Information Brake System Top View Silhouette of Brake System components 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. 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 5-12 Section 5: Reference Information Exhaust System Top View Silhouette of the Exhaust System components Reference Information 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 Reference Information 5-13 Section 5: Reference Information 2022 SSV HEV ONLY 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021 5-14 Section 5: Reference Information Roof Bow Highlighted For Light Bar Installation Reference Information Area In Bed To Avoid 2021-2022 F-150 SSV and Responder Modifier Guide, 08/2021