F-SERIES EXCURSION Expedition E-SERIES

FOR 2002

North American Truck

Special Vehicle Engineering
 2002 Ford Truck “What’s New” Guide

The purpose of this guide is to provide some advance insight into 2002 model
year Ford Truck product features that may assist final stage manufacturers, and
vehicle alteration companies, in preparing their production process.

This guide is for reference only, reflecting information available as of September,

2001 and is subject to change without notice. It should be used in conjunction
with other related Ford publications listed below. Methods to obtain these and
other useful publications are described further in this manual.

• Ford Truck Body Builders Layout Book

• Incomplete Vehicle Manual

This manual is the property of Ford Motor Company. Reproduction or use for any other
purpose, without the permission of Ford Motor Company, is prohibited.
 TABLE OF CONTENTS

Page Number Subject

1 Body Builder Quality Programs

1 Job #1 Timing
2-3 F-150
4-5 F-250/350/450/550 Super Duty
6 PTO Circuit Installation, Electrical Wiring
7 Trailer Tow Wiring Tap Schematic
8 Schematic for Adding Lights or Electrical Devices
9 F-650 Super Duty
10 F-750 Super Duty
11 F-53 Class A Motorhome Chassis
12-13 E-Series Van / Cutaway / Stripped Chassis
14-15 E-550 Super Duty Cutaway
16 E-Series Customer Access Circuits, Electrical Wiring
17-18 Excursion
19 Expedition
20 Tire Pressure Awareness Label
21 Truck Body Builders Advisory Service Website
22 Obtaining Publications
• Ford Truck Body Builders Layout Book
• Incomplete Vehicle Manual
• Ford Recreation Vehicle and Trailer Towing Guide
• Service Publications (i.e. Wiring Diagrams, Shop Manuals)
• Body Builder Quality Bulletins
23 Important Phone Numbers and Web Sites
 Body Builder Quality Programs
The following organizations are established to provide technical assistance to vehicle modifiers of Ford Truck
chassis. They are part of the Special Vehicle Engineering Department within the Ford North American Truck
Consumer Business Group.

• TRUCK BODY BUILDER ADVISORY SERVICE

Provides daily technical assistance for truck body builders.
Phone: 877-840-4338
Fax: 313-594-2633
Web Site: www.fleet.ford.com/truckbbas
E-Mail: bbasqa@ford.com
F-Super Duty Class “A” Chassis Motorhome Liaison: 313-337-6520 Fax: 313-621-8032

• MODIFIED VEHICLE ENGINEERING & QUALITY PROGRAMS

Responsible for qualifying the engineering process control capability of final stage manufacturers under
these programs:
– QVM-Ambulance Quality Program
– QVM-Motor Home & Transit Bus Quality Program
– Conversion Van Quality Program
– F-Series Quality Program
– Adaptive Mobility Quality Program

• MVE SHIP-THRU SECTION

Responsible for qualifying the engineering process control capability of companies that up-fit vehicles in
the ship-thru process.

Assembly Plant Job #1 Timing

2002 Model
Vehicles Assembly Plant Job #1

F-150 Regular and SuperCab Norfolk Assembly Plant 7/30/01

Kansas City 8/20/01
Ontario Truck Plant 8/27/01

F-150 SuperCrew Kansas City 8/20/01

Super Duty F-Series

F-350/450/550 Chassis Cab
And Pickup Box Delete: Kentucky Truck Plant 7/16/01
F-250/350 Pickup: Kentucky Truck Plant 7/16/01
F-250/350 Pickup: Cuautitlan, Mexico 8/13/01
F-650/750: Cuautitlan, Mexico 8/27/01

F-53 Class A Motor Home Chassis

15,700, 18,000, 20,500-lb. GVWR: Detroit Chassis Plant 7/26/01
22,000lb. GVWR: Detroit Chassis Plant 7/26/01

Excursion Kentucky Truck Plant 7/16/01

Expedition Michigan Truck Plant 7/23/01

E-Series (except E-550) Lorain Assembly Plant 7/23/01

E-550 Super Duty Cutaway Lorain Assembly Plant 1st Quarter 2002
1
 F-150
2002 MAJOR PRODUCT FEATURE CHANGES
■ MODEL/TRIM:
• New King Ranch trim package available on SuperCab.
• Harley Davidson F-150 features 5.4L Supercharged 2V engine. “Supercharged”
added to fender/tailgate badges; revised grille (larger quasi-billet chrome bars with
larger spacing between bars), and flame accents added to the exterior upper tape
stripe and interior front and rear console covers (Job #1 1/7/02)
• New FX4 Off-Road Equipment Group features 17" 5-Spoke Cast Aluminum
Wheels, “FX4 Off-Road” decal, skid plates and white colored branded Rancho
shock absorbers. Also includes color-keyed grille insert, wheel lip moldings and
front bumper top cap (Dark Shadow Gray with XLT and Arizona Beige or Silver
with Lariat). Matching lower two-tone and unique paint break stripe is optional.

■ POWERTRAIN/CHASSIS:
GVWR/GCWR
• 6,050 lbs. GVWR replaces the 5,600 lbs. GVWR (Regular Cab) and the 6,000 lbs.
GVWR (SuperCab) as standard with 4.2L engine (Optional 6,000 lbs. GVWR
Payload Package No. 2 available last year on Regular Cab is also cancelled).
• 7700 Payload Group renamed 7700 Lb. Payload Group A (7,700 lbs. GVWR/3.73
axle/13,500 lbs. GCWR/8,800 lbs. max. trailer weight). New 7700 Lb. Plus Payload
Group B is available on 139" wheelbase Regular Cab and Supercab 4x2 models
only and includes Group A content plus upgraded 22-plate auxiliary transmission
oil cooler, Class III Trailer Tow Group and 4.10 limited slip axle (7,700 lbs.
GVWR/4.10 axle/15,000 lbs. GCWR/8,800 lbs. max. trailer weight).
Engine
• Heavy Duty Electrical/Cooling Group cancelled. 72 amp.-hr. battery and auxiliary
automatic transmission oil cooler (number of plates varies by application) are
included with Class III Trailer Tow Group and 7700 Lb. Payload Groups A and B.
The 7700 Lb. Payload Groups also include an upgraded radiator with 1.42" core
thickness.
• 4.6L engine includes new integrated air fuel module (IAFM), to include air cleaner
assembly, air filter, mass air flow sensor and AIT sensor to meet 2002 emissions
requirements.
• 6 rib serpentine belt replaces 8 rib belt/pulley (except Lightning and Harley
Davidson).
Tires/Wheels
• New spare tire lock is standard (late availability).

■ EXTERIOR:
Paint and Trim
• Colors added are Dark Shadow Grey and True Blue. Color availability expanded
are Estate Green available on XLT and Lariat and Toreador Red available on
Lariat. Colors deleted are Wedgewood Blue and Island Blue.

■ INTERIOR:
Comfort and Convenience
• Interior revisions to meet FMVSS 201Occupant Protection in Interior Impact: New
windshield header assembly and A-pillar inner (similar as 2002 Expedition); New
grab handles (added foam); New headliner assembly (added foam), coat hooks,
sun visor attaching brackets and safety belt with adjustable D-ring; New side rails,

2
 F-150
2002 MAJOR PRODUCT FEATURE CHANGES (continued)
front and rear door and rear quarter trim (adding ribbing and cartridges to
enhance occupant protection (Job #1 1/2/02).
• Air Conditioning is standard with XL trim (optional with Work Truck Group).
• New electronic automatic temperature control air conditioning is standard on
SuperCrew Lariat and King Ranch models (late availability on SuperCab).
• New “Fuel Cap Loose” warning light.

3
F-250/350/450/550 Super Duty
2002 MAJOR PRODUCT FEATURE CHANGES
■ MODEL/TRIM:
• New F-450-550 SuperCab DRW 161.8" WB/60" Cab-to-Axle (CA) Chassis Cab
models.
With the availability of SuperCab on F-450 and F-550, this popular cab
configuration is available on all F-Series from F-250 to F-750.
- Back seats can accommodate 3 passengers
- Also suitable for stowage of tools or cargo
• Pickup box delete option is now available on long wheelbase (8-foot box) F-350
SRW models.
■ POWERTRAIN/CHASSIS:
GVWR/GCWR
• Conventional towing ratings increased to a maximum of 12,500 lbs. (from 10,000
lbs.) with 6.8L V-10 (4.30 axle) and 7.3L Diesel engines (late 2001 MY change).
• Maximum GVWR increased to 12,500-lbs. (from 11,500-lbs.) on 49-states F-350
DRW Pickup models with 7.3L Diesel engine (172.4” WB Crew Cab remains at
11,500-lbs. GVWR; California remains at 11,000-lbs. GVWR). Conventional trailer
tow ratings increased to a maximum 23,000-lbs. GCWR/13,500-lbs. trailer weight
(from 20,000-lbs. GCWR/12,500-lbs. max. trailer weight) on F-350 DRW Pickup
models with 6.8L V-10 (4.30 axle) and 7.3L Diesel (4.10 axle) (Effective
December, 2001).
Axles
• Synthetic oil lubrication included with all 30,000-lb. GCWR option packages (all
other applications include mineral oil lubrication).
Engine
• 6.8L Bi-fuel (Gas/LPG) Vehicle Program is canceled.
• G05 Hybrid/OA long life coolant (100K miles) standard for all applications.
Electrical
• 6G 130 ampere/1950 watt alternator standard for all engines. Dual 130 ampere/
1950 watt alternators optional with 7.3L diesel engine.
• 7/4 pin trailer towing connector revised to 7 pin connector.
• New interior power distribution junction box combines the power distribution box
with the junction box and places all fuses under the instrument panel.
Fuel
• Dual Fuel Tank option (19-gal. midship/40-gal. aft-of-rear axle) is available on
DRW Chassis Cabs with 7.3L V-8 Diesel. Includes new instrument panel
mounted tank selector control switch.
Greater fuel capacity means increased range —fewer stops. That’s the idea
behind the new dual fuel tank option. A tank selector control switch is conveniently
mounted on the instrument panel.
Transmission
• ZF-650OD 6-speed manual overdrive transmission replaces the 5-speed manual
overdrive transmission as standard with 5.4L V-8 and 6.8L V-10 engines.
Suspension
• Auxiliary rear springs are now standard on all models (Late 2001 MY change)
Tires
• New 225/70R19.5F traction tire is available on 4x2/4x4 in the Traction Package or
on 4x4 in the Max Traction Package on F-450-550 models. 225/70R19.5F all-
terrain tire will be phased out in January, 2002.

4
 F-250/350/450/550 Super Duty
2002 MAJOR PRODUCT FEATURE CHANGES (continued)
■ EXTERIOR:
Lighting
• New “jeweled” single beam complex reflector headlamp with separate park and
turn lamps are standard with XLT, Lariat and Lariat LE.
Mirrors
• Trailer tow mirrors include new forward fold feature.
The popular manual telescoping/power glass trailer tow mirrors now fold both
forward and backward.
Paint and Trim
• Colors added are Arizona Beige and Dark Shadow Grey. Colors deleted are
Harvest Gold and Bright Amber.
• Two new exterior color schemes for Lariat LE include Ebony monotone exterior or
Ebony/Dark Shadow Gray/Ebony two-tone exterior.
• Three new two-tone tape break stripes/color combinations.

■ INTERIOR:
Comfort and Convenience
• New roof/headliner mounted ride handle for the front seat outboard passenger is
standard for all cab styles. Crew Cab also includes standard L.H./R.H. ride
handles for rear seat outboard passenger seating positions (Handles are same as
Excursion).
• XLT cloth sun visors with L.H. map strap and R.H. uncovered mirror made
standard on XL models.
• New larger Lariat overhead console includes sun glasses bin, garage door opener
bin and trip computer with distance-to-empty (deleted with dual fuel tanks),
outside temperature and compass displays (Similar to F-150 console).
The new, larger Lariat Overhead Console extends this popular feature to the
F-250 through F-550 range, adding even more storage convenience.
• SuperCab rear door trim panels are revised to include new standard L.H./R.H.
cup holders for 12-oz. cans and 20-oz. bottles.
SuperCab rear seat passengers can now enjoy the convenience of a cup holder,
integrated into the rear door trim panel on both right hand and left hand sides.
• New Security Lock Group is optional on XLT and standard on Lariat and Lariat LE
and includes Remote Keyless Entry and new Auto Lamp and Auto Lock/Relock
features.
Instrumentation
• Transmission fluid temperature gauge replaces battery gauge with automatic
transmission applications (Battery warning light remains).
The transmission fluid temperature gauge allows the driver to monitor fluid
temperature and alter usage conditions accordingly.
Seating
• New XL cloth seat trim materials are “Hopsack” side facings/bolsters with “Links”
inserts (replaces Fargo/Summit cloth, sew style carryover).
• New sew styles and foam for XLT, Lariat and Lariat LE Regular Cab and Crew
Cab seats for comfort and appearance. New XLT cloth seat trim materials are
‘Elliott” side facings/bolsters with “Bazaar” inserts (replaces Beacon/Dillon cloth).
• Inboard arm rests added to front and rear Captain’s Chairs.
• Crew Cab 6-way power adjustable front outboard passenger seat is optional on
XLT and standard on Lariat and Lariat LE.
5
 ELECTRICAL WIRING
POWER TAKE-OFF CIRCUIT INSTALLATION
The Body Builder must provide a PTO Circuit to alert the PCM to PTO operation. Failure to provide this circuit
may result in erroneous emission codes, and inadvertent illumination of the “Service Engine Soon” light during
PTO operation.
Circuits 294 (WH-LB) is located in the center of the instrument panel, labeled “Power Take-Off Circuit” and the
circuit 322 (LB-Y) is located to the right of the parking brake labeled “Customer Pass-Thru/PTO and CTO
Circuits” (see Figure A). They are near the customer pass-thru circuits, and are blunt-cut with shrink wrap
tubing over the cut ends. They are easier to access from the front of the instrument panel (IP) by removing
the access panel below the steering column (4 quarter-turn fasteners).
Splice circuit 294 (WH/LB) to the body builder provided wire that connects to the positive side of the PTO
indicator switch or PTO control relay. Splice circuit 322 (LB-Y) to the body builder provided wire that connects
to the positive (switched) side of the PTO indicator light. (See Figure C1). In electrically-actuated PTO
systems, must be relay isolated from the circuit containing the solenoid or PCM DAMAGE COULD RESULT
(See Figure C2).

FIGURE A - VIEW UNDER DASH — SUPER DUTY F-SERIES

FIGURE C1 - SUPER DUTY F-SERIES FIGURE C2 - SUPER DUTY F-SERIES

6
 Power Distribution Junction Box

For the 2002 Model Year, Super Duty F-Series (F-250/350/450/550) vehicles have had extensive electrical
changes. All fuse numbering has changed with the combination of the Power Distribution Box and the
Junction Box into the Power Distribution Junction Box (PDJB). The PDJB is found under the dash, below the
steering wheel and behind the modesty panel. Another change has been the addition of relays to Trailer Tow
Stop/Turn Circuits 52 (Yellow) and 64 (Dark Green). This change will require SUB installers, who have used
the trailer tow connector to connect their SUB, to rethink their connection. The relay isolation of circuits 52
and 64 require the connection of some load to the Ford Stop/Turn connectors or the turn signals will flash as
if a bulb were burned out. Either connect your SUB Stop/Turn signals to the Ford Stop/Turn signal connectors
or connect a resistive load to each of the connects.

Trailer Tow Second Unit Body Wiring Tap Schematic –

Super Duty F-Series

7
 Changes To Circuits

Check your fuses and circuits for the 2002 Model Year. DO NOT ASSUME that there are no changes for the
2002 Model Year F-250/350/450/550 vehicles. The DRL control circuits are new for 2002. The elimination of
the GEM has also brought about many electrical changes. Check your circuits and your fuse numbers and if
you have questions call the Ford Truck Body Builders Advisory Service at (877) 840-4338 or E-mail us at
bbasqa@ford.com. Contact us before applying power to any circuit you are unsure about. This may take more
time now, but it will save you from damaging the Ford vehicle’s electrical system. Take the time to contact us
and you will save more than time.

Electrical Wiring Schematic for

Adding Lights or Electrical Devices

8
 F-650 Super Duty
2002 MAJOR PRODUCT FEATURE CHANGES
■ MODEL/TRIM:
• Lo-Profile Package (July 2001 Introduction)
– 8.5" frame
– 19.5" 8-hole disc wheels
– 245/70R 19.5G tires
- G159 front
- G124 rear
– Tuned springs and shocks
– Improved braking for lighter GVW’s
• Rescue Package (available December, 2001)
– Lo-Profile 20,000 lb. GVWR
– 108" CA
– HAS 120 single axle air suspension with dump valve – Hendrickson system
Dump valve provides “kneeling” feature
– 225 hp Cummins engine with Allison 2400 5-speed automatic transmission
– 270 amp alternator
– Hydraulic brakes
– 18K GVWR available

■ POWERTRAIN/CHASSIS:
GVWR/GCWR
Engine
• 6 rib serpentine belt replaces 8 rib belt/pulley.
• Caterpillar 3126 Low Emission Vehicle (LEV) available
• Allison AT545 automatic transmission now standard w/Cummins 210 HP/520 lbs.-
ft. torque
• Aluminum wheels (Lo-Pro) available as stand-alone option

■ EXTERIOR:
Paint and Trim
• Chrome grille and chrome headlight bezels available as a stand-alone option
• Telescoping mirrors available

■ INTERIOR:
Trim
• Medium Flint interior replaces Medium Graphite

9
 F-750 Super Duty
2002 MAJOR PRODUCT FEATURE CHANGES
■ MODEL/TRIM:
• New F-750 tractor package. Targeted at the beverage industry and single axle
tractor applications
– 158" WB Regular Cab
– 179" WB SuperCab.
– Available with Caterpillar and Cummins diesel engines, and MD Automatic
transmission

■ POWERTRAIN/CHASSIS:
GVWR/GCWR
• 30,000 lb. GVWR
- Allison AT545 Automatic transmission is now standard with Cummins
210hp/520 lb.ft. torque. This replaces the manual transmission as standard.
• 33,000 lb. GVWR
- Allison MD-3060CR automatic transmission now standard with Caterpillar
210 hp/605 lb. ft. torque. This replaces the manual transmission as standard.
Engine
• 6 rib serpentine belt replaces 8 rib belt/pulley
• Caterpillar 3126 Low-Emission Vehicle (LEV) available

EXTERIOR:
Paint and Trim
• Chrome grille and chrome headlight bezels available
• Telescoping mirrors available

INTERIOR:
Trim
• Medium Flint interior replaces Medium Graphite
• Tilt wheel available on 33K GVWR

10
F-53 Class A Motorhome Chassis
2002 MAJOR PRODUCT FEATURE CHANGES
■ MODEL/TRIM:
• Front GAWR increased to 7,500 lbs.
• Rear GAWR increased to 14,500 lbs.
• Shocks and springs retuned to match higher GAWR

■ POWERTRAIN/CHASSIS:
GVWR/GCWR
• 22,000 lb. GVWR and 4-Wheel/4-Channel ABS
• Visual differences between 20,500 lb. vs. 22,000 lb. GVWR —
22,000 lb. GVWR has:
– Tape Tag on axle tube with P/N – white and blue lettering
– Paint dot on rear of axle housing
– Springs have P/N painted in green on top leaf
– Bar coded incomplete vehicle label has GVWR listed on it
Engine
• 6 rib serpentine belt replaces 8 rib belt/pulley

11
E-Series Van / Cutaway / Stripped Chassis
2002 MAJOR PRODUCT FEATURE CHANGES
New AC Scroll Compressor
New Base Mirror (Van)
New Telescopic Mirror (Cutaway) • New E-Coating on Frames (Replaces Wax Coat/Paint)
MODEL/TRIM:
Standard Features Include:
• Tilt Steering Wheel
• Speed Control (Standard on Recreational Vans/Optional on
Commercial Vans)
• Back Lit Switches
• Rear Chrome Step Bumper (Contour Chrome Bumper - Optional)
• Rear Vinyl Floor Covering (Maslite) w/delete option
POWERTRAIN/CHASSIS:
Rear Axle
• New 4.56 Limited Slip (LS) Axle (5.4L NGV, 6.8L) - E-450 Cutaway
• New 4.10 Limited Slip (LS) Axle (7.3L Diesel) - E-450 Cutaway
Engine
• New Fuel Pump - Turbine Type Pump (Replaces Rotor)
• AC Scroll Compressor
New AC Scroll Compressor helps increase durability. Location has
not changed, but plumbing connections are all-new for 2002.
• New Aluminum Aux. Heat & A/C Tubes Lines
• New Dual Idler Bearings (FEAD) - 7.3L Diesel
New Dual Idler Bearings help improve high mileage life
• Improved Belt Life & Noise on All Engines (Orion Material)
• New Engine Oil Cooler - 6.8L
• New Nickel Plated Spark Plug Shell
• New Stainless Steel Engine Cup Plug
• Improved NVH - 4.6L, 5.4L, 6.8L - Valley Stuffer
• New Anti Splash Baffle in Master Cylinder
Frame
Suspension
• New Upper Ball Joint Wear - Added Grease Plugs.
• New Lower Front Shock Bushing Material (Urethane)

EXTERIOR:
Mirrors
• New Exterior Mirrors (First Quarter, 2002)
Cutaway features Standard Trailer Tow Mirror similar to the one
featured on F-Series. The E-Series Van with Trailer Tow Option will
New Brake Caliper Shield also receive a new base mirror at mid-model year.
Paint and Trim
• New Wheel Covers Wire Diameter & Dimension Controls
• New Caliper Shield (Stone Pecking) (E-350, E-450 Only)
• Sound Deadening and Sealing
• Thicker Spray on PVC in Wheel Wells
• Extensive Body Sealing
• New Front Door Hinge Bushings (Sprayed Teflon vs. Bonded)
• Running Boards Optional on Vans and Cutaways

3 Dome Lights (Standard)

12
E-Series Van / Cutaway / Stripped Chassis
2002 MAJOR PRODUCT FEATURE CHANGES (continued)
INTERIOR – Comfort and Convenience (continued):

New Dual INTERIOR:

Idler Bearings Comfort and Convenience
replace • New Illuminated Rear Aux. Heat & A/C Switch
• New CD6 Player - Optional w/Dual Media
former bear-
• New Dome Light On/Off Switch (Rear Door) and 3
ings for Lamps Standard
improved high • Diesel Engine Cover (4.2L, All E-Traveler & 7.3L Diesel)
mileage life • Dash Panel Sound Absorber Front
• Carpet - Added Binder and Upgraded Padding
• Wheel House Covers Added
• Rear Vinyl Floor Covering (Maslite) - Upgraded padding.
• New Dash Cowl Reinforcement—Stiffer I/P cross car
beam.
OLD NEW • Grab Handle - A-pillar/passenger side.
• Floor Covering, front & rear (Std.)
• Under Seat Storage - passenger side
• Armrest - inboard, all front seats
Door Trim
• New front door trim panels (Late Availability)
Instrumentation
• New Low Fuel Warning Light - I/P Cluster.
• New Speed Control “On” Indicator Light - I/P Cluster.
Seating
New Valley Stuffer improves NVH • New Seat Material - Improved vinyl (Stockton 2
Directional).
• New Seat Material - Increased foam density.
• New Seat Material - Increase flex mat wire gage/added
hook.

Instrument Panel Sound Absorber (NVH)

New Instrument Panel Reinforcement New Front Door Trim Panels

13
 E-550 Cutaway (late availability)
2002 MAJOR PRODUCT FEATURES
Roof marker Lights (Optional)
Telescopic Mirror
Running Boards (Std.)
Wheel Lips (Std.)
Distinctive Grille and
Lower Bumper Fascia
MODEL/TRIM:
• Five wheelbase lengths: 159.5", 177.5", 191.5", 209.5", 233.5"
Five wheelbase lengths means E-550 will be the vehicle of choice
for a greater range of commercial applications.
POWERTRAIN/CHASSIS:
GVWR/GCWR
• 17,500 lbs. and 19,000 lbs. GVWR availability.
• 20,000 lbs. max. GCWR
The new 17,500 and 19,000 lbs. GVWR allows E-550 to
accommodate larger payloads.
GAWR
• 6,000 lbs. front; 11,500 lbs. or 13,500 lbs. rear.
Engine
• 6.8L V10 gas or 7.3L diesel engine. (Diesel 49 states only).
Fuel Tanks
• 55 gallons Aft-of-axle (Standard)
Tires/Wheels
• 19.5 in. wheels and tires
• Steel wheels (Standard)
• Polished aluminum wheels (Optional)
Transmission
• 4-Speed electronic automatic with overdrive (4R100)
Maneuverability
Reduced turning diameter vs. E-350/E-450
Tighter turning diameter makes E-550 a perfect vehicle for moving
about city streets for local pick up and delivery.
EXTERIOR:
Lighting
• Roof marker lights (Optional)
Mirrors
• New trailer tow mirrors (Standard); Mirror Delete Option available
New standard manually-telescoping trailer tow mirrors feature
electrically adjusted glass and are perfect for 96"-wide second-unit
bodies.
Trim
• Running boards (Standard)
Standard running boards make ingress and egress easier.
• Wheel lips (Standard)
• New grille and lower bumper fascia
Distinctive new Super Duty grille and lower bumper fascia add to
the overall good looks of E-550
14
 E-550 Cutaway (late availability)
2002 MAJOR PRODUCT FEATURES (continued)
Interior:
Comfort and Convenience
• Front Door Trim Panel
Front door trim with convenient storage
pocket
• Premium Plus CD6 Radio (Optional)
• Tilt Wheel (Standard)
• Dual Media Radio
Provides in-dash single CD player and
cassette
• Speed Control (Optional)

Functional:
Frame
• Hour-glass design with common frame
New Front Door Trim Panels section around rear axle
Common frame section with hour-glass
shape and flat frame design to facilitate
ease of body installation.
• Multi-piece Construction
• Flat Frame Design
• Stiffer frame (than E-450)
• Removable engine crossmember for
servicing front engine oil pan
Front Axle/Suspension
• Solid forged I-beam front axle
• Tapered leaf springs
• Gas shocks with 35 mm bore and 580 mm
Stiffer Frame
extended length
• 36 mm diameter torque bar
Steering
• Haltenberger type steering geometry
• Steering gear, heavy duty-high output
• Wheel cut angle, 40 degrees
Rear Axle/Suspension
• Axle, Dana 135 Medium Duty (13,500 lbs.
Flat Frame Design capacity)
• Tapered leaf springs (11,500 lbs. standard,
13,500 lbs. optional)
• Gas shocks with 35 mm bore and 703 mm
extended length
• 31 mm diameter torque bar

Common frame
section & hour-glass
shape Crossmember Front Suspension
15
 Electrical Wiring
CUSTOMER ACCESS CIRCUITS
This chart contains the changes and additions to the Customer Accessible Circuits for 2002 E-Series
vehicles. Changes to other circuits may have occurred in circuits not designated as Customer Access Circuits.
For this information refer to the 2002 Ford E-Series Wiring Diagrams Book available from Helm, Inc.
(800) 782-4356 or www.helminc.com.
CIRCUIT CHART
Circuit Color Wire Functional Description
Number Code Gauge
2 WH/LB 18 Right turn signal
3 LG/WH 18 Left turn signal
14 BR 18 Marker lamp feed to electric brake controller
22 LB/BK 12 Trailer brake controller or B + feed
43 DB 12 Electric trailer brake controller
49 O 12 Relay feed ignition run
52 Y 16 Fused left hand stop/turn
53 BK/LB 18 Courtesy lamps
59 LG/YE 18 Courtesy switch feed
64 DG 16 Fused right hand stop/turn
206 W 16 Ground
511 LG 18 Center high mount or lamp feed stop
648 WH-PK 18 Clean tach output (CTO)
867 DB 12 Customer pass-thru circuits
868 GY/R 12 Customer pass-thru circuits
962 BR-W 16 Relay feed marker lamps
963 BK-LG 16 Relay feed backup lamp

THE “CHMSL” ELECTRICAL CONNECTION FOR A

STRIPPED CHASSIS IS PROVIDED IN A DETAILED
SCHEMATIC, WHICH IS PACKAGED WITH THE BODY
BUILDER ELECTRICAL CONNECTORS

TO INSTALL “CHMSL”, UNWRAP TAPE FROM HARNESS

IN THIS AREA AND REMOVE JUMPER CONNECTION TO
EXPOSE THE “CHMSL CONNECTOR”

FRONT OF
VEHICLE

16
 Excursion
2002 MAJOR PRODUCT FEATURE CHANGES
MODEL/TRIM:
• New exterior colors: True Blue (replaces Deep Wedgewood Blue), Aspen Green
(replaces Dark Satin Green), Medium Wedgewood Blue - XLT only (replaces
Medium Steel Blue), Mineral Gray - Limited only (replaces Arizona Beige), Silver
Birch - XLT only (replaces Silver).
• Revised Fleet Special Service Package
– Power heated, sail mounted exterior mirrors
– Seat configuration changes
• Deleted optional Limited Feature Vehicle (No Boundaries Package)

POWERTRAIN/CHASSIS:
Engine
• New G05 Hybrid/OA long life (100K mile) engine coolant
Electrical
• 130 amp./1950 watt 6G alternator w/central load dump capability (CLD) now
standard on gas engines, replacing HD alternator
• Heavy Duty Trailer Tow Package revised to eliminate 7/4 way adapter
• New interior power distribution junction box combines the power distribution box
with the junction box and places all fuses under the instrument panel

EXTERIOR:
Lighting
• Single beam jeweled headlamps replace aero halogen headlamps.
• Modified position and parking light assembly.
Mirrors
• Fold forward feature added to optional Telescoping Trailer Tow Exterior Mirrors
Paint and Trim
• Deleted Chestnut exterior color
• Medium Platinum XLT bodyside cladding replaces Medium Flint
• Chrome insert added to Limited bodyside cladding
• New Paint Stripe Colors: Mocha (replaces Saddle), Medium Dark Charcoal
(replaces Blue)
Windshield Wipers
• New ‘smart” windshield wiper motors (front and rear)

INTERIOR:
Comfort and Convenience
• Medium Flint interior color replaces Medium Graphite (XLT only)
• Revised Comfort Group
• Revised Convenience Group
• 12 oz. Lanier carpet replaces 12 oz. Midway
• 12 oz. Lanier floor mats replace 12 oz. Midway on XLT.
• Fixed accelerator and brake pedals now standard on XLT
• Standard auto door locks
• Integrated DVD System replaces Video Cassette Player in Rear Entertainment
System (Late Availability)
• Rear Seat Entertainment System now optional on XLT

17
 Excursion
2002 MAJOR PRODUCT FEATURE CHANGES (continued)
Instrumentation
• Standard Electronic Automatic Temperature Control (EATC) on Limited.
• US Hybrid III Instrument Cluster replaces US Instrument Cluster
• Deleted Mini-overhead console
• New optional Ultimate Group on Limited
Seating
• New seat sew styles
• Elliott cloth bolster seat material replaces Beacon
• Nudo leather replaces “sheared” nudo leather on Limited
• New optional 2nd row bucket seats on Limited
• Extended lumbar added to all 1st row captains chairs and 40/20/40 bench seats
• Inboard arm rests on captains chairs have increased length

18
 Expedition
2002 MAJOR PRODUCT FEATURE CHANGES
MODEL/TRIM:
Revised Eddie Bauer Premier Package.

POWERTRAIN/CHASSIS:
Axles
• 3.55 rear axle ratio replaces 3.31 on 4x2 w/4.6L engine.
• 3.73 rear axle ratio high altitude restriction removed on 4x4 w/5.4L engine.
Engine
• 6-rib serpentine belt replaces 8-rib belt/pulley.
• Added cylinder block ribbing to 5.4L engine for NVH improvement.
• New G05 Hybrid/OA long life (100K mile) engine coolant.
• Wisconsin added to list of U.S. States (7 total) requiring engine block heater.
Available through FCSD in other states.
Steering
• Assist power steering replaces variable assist.

EXTERIOR:
Paint and Trim
• Deleted exterior colors: Dark Highland Green, Dark Toreador Red, Deep
Wedgewood Blue, Estate Green.

INTERIOR:
Seating
• Optional Rear Seat Entertainment System on both XLT & Eddie Bauer.

19
 Tire Pressure Awareness Label

Ford Motor Company is equipping all E-Series and F-Super Duty models with a Tire Pressure Awareness
label that will be located inside the fuel door. For incomplete vehicles without fuel doors, the label will be
placed in the incomplete vehicle package. The label is to be installed by the Final Stage Manufacturer in a
noticeable location near the fuel tank fill location. This label contains tire size and front/rear pressures. The
label must be applied to a clean surface.

E-350 F-Series

E-450

Incomplete Vehicle
20
Truck Body Builders Advisory Service
Website
(http://www.fleet.ford.com/truckbbas)

Hot Off The Press: Displays latest up-to-date publications available to Body
Builders

Truck Support Contacts: Displays frequently requested phone and fax numbers
These may be useful in answering your truck-related ques-
tions.

Body Builder’s Layout Book: Provides access to and order capability for Body Builder
Layout Book

Bulletins: Displays the latest Bulletins relative to CVQP, QVM and

MVE programs

21
 OBTAINING PUBLICATIONS
Ford Truck Body Builders Layout Book
Order and access via www.fleet.ford.com/truckbbas.

Incomplete Vehicle Manual

Access at www.fleet.ford.com/truckbbas.

Ford Recreation Vehicle and Trailer Towing Guide

The guide covers cars and light trucks, and includes trailer and camper weight ratings and the list of vehicles
suitable for flat-towing. A copy can be obtained by contacting the Ford RV Information Service at (800) 245-
7343, leave name and shipping address, or Fax to (248) 936-3300.

Service Publications
The “Ford Technical Publications Catalog” list the service publications available, and includes pricing, an order
form, and a mailer. Contact Helm, Inc. at 800-782-4356.
Useful publications include “Truck Wiring Diagrams” and the “Service Specifications” book.

Body Builder Quality Bulletins

Body Builder Quality Bulletins provide key information to assist Body Builders in interfacing with a Ford
chassis:
• Conversion Van Quality Program (CVQP) Bulletins
• Qualified Vehicle Modifier (QVM) Bulletins
• Modified Vehicle Engineering (MVE) Bulletins
These bulletins can be accessed via the web at www.fleet.ford.com/truckbbas.

22
 IMPORTANT PHONE NUMBERS AND WEB SITES
INTENDED FOR GENERAL USERS & CUSTOMERS OF COMPLETED VEHICLES
Ford Customer Assistance
Customer Assistance Center: 800-392-3673
Roadside Assistance Center: 800-241-3673

Web Site: www.ford.com

Ford RV (Customer Assistance Center)

To locate the nearest RV service center: 800-444-3311

INTENDED FOR FINAL STAGE MANUFACTURERS & VEHICLE MODIFIERS

Ford Truck Body Builders Advisory Services (BBAS)

Truck: 877-840-4338
Fax: 313-594-2633
Web Site: www.fleet.ford.com/truckbbas
E-Mail Address: bbasqa@ford.com

List of Ford Pool Accounts and Qualified Vehicle Modifiers

www.fleet.ford.com/truckbbas
Click on “Specialty vehicles” on the navigation bar and select the desired vehicle type.

F-Super Duty Class A Motorhome Chassis Liaison

313-337-6520
Fax: 313-621-8032

Ford Alternative Fuels Information

Vehicle models available, list of authorized Ford dealers, and Leaf & Road Newsletter.
877-ALT-FUEL
(877-258-3835)

Ford Component Sales

734-523-5702
Fax: 734-523-5917

E-Series Aft-of-Axle Fuel Tank Kit (gasoline and diesel)

TDM, Inc.: 800-540-3913
Alternate: 734-458-9100
Fax: 734-458-9118

Dealer Special Order, DSO Fleet Sales

1-800-34-FLEET
Select #4

23
 North American Truck
Special Vehicle Engineering Department

Information herein was correct when approved for printing. Ford Motor Company reserves the right to
discontinue or change at any time, specifications, designs or programs without incurring obligation.

SVED-09-01 August, 2001 AOC 16126 Litho in USA