FORD F150 Body Builders Layout Book Instruction Manual

F150 Body Builders Layout Book
Instruction Manual

About this Publication

It is recommended to review this manual in full. The BBLB is a live document which can be viewed on https://www.fordtechservice.dealerconnection.com/ or https://www.ford.com.au/owners/vehicle-support/body-eauipment-manuals/. It is the vehicle converters responsibility to review the online version for the most current information prior to starting any conversion. For further information please contact your
National Sales Company representative, or local Ford Dealer.
In addition to the detail available in this manual, further information related to servicing and maintenance of Ford vehicles is available using a subscription service via
https://www.motorcraftservice.com/ or see your National Sales Company representative, or local Ford Dealer.

Introduction

Important Notices
The information described herein is believed to be correct at the time of publication, but accuracy cannot be guaranteed. Ford reserves the right to discontinue models or change specifications or designs at any time without notice and without incurring any obligation.
Commercial and Legal Aspects Terminology
NOTE:
Any modifications to the vehicle must be noted in the owner’s handbook or new descriptive literature included with the owner’s documentation.
The term “Vehicle Converter” refers to any party altering the vehicle by converting the body and adding or modifying any equipment not originally specified and or supplied by Ford. Similar terms such as Vehicle Converter, Up fitter, Body Builder may be referenced in this manual and also refer to any party altering the vehicle by converting the body and adding or modifying any equipment not originally specified and or supplied by Ford.
The term “Unique component” or similar wording refers to non-Ford specified or after sale components which are fitted by a Vehicle Converter and are not covered by any Ford warranty.
Warranty on Ford Vehicles
Please contact the National Sales Company in the country where the vehicle will be registered for details of the terms of any applicable Ford warranty.
The Vehicle Converter should warrant its design, materials and construction for a period at least equal to any applicable Ford warranty.
The Vehicle Converter must ensure that any alteration made to a Ford vehicle or component does not reduce the safety, function, or durability of the vehicle or any component and does not make the vehicle or any component non­ compliant with regulatory requirements.
The Vehicle Converter shall be solely responsible for any damage resulting from any alteration made by the Vehicle Converter or any of its agents to a Ford Vehicle Component.
In consideration for Ford making this information available to Vehicle
Converters, a Vehicle Converter using this manual agrees it will not make any claim against Ford any cost or loss (including any consequential damages) rising from work performed by the Vehicle Converter.
Emissions Performance & In­ **service compliance
** Ford has developed the vehicle to comply with all applicable regulatory requirements and any modification and alterations to the vehicle must remain within such regulations.
Fitment of Parts and Accessories We strongly recommend the use of only Ford Genuine and Ford Licensed Accessories. Every Ford Genuine and Ford Licensed Accessory has undergone a rigorous evaluation process by Ford engineers to ensure it’s fully compatible with your vehicle, ensuring you’ll get optimal integration and performance.
We engineer these parts for your vehicle o meet or exceed our specifications. Use of other parts could impact vehicle performance, emissions and durability. Your warranty could be void for any damage related to use of other parts.
Legal and Vehicle Type Approval

• All components embodied on  Ford vehicles are approved to the applicable legal requirements.
• Ford vehicles have Type Approval for the intended marketing territories.

WARNING: Exception – Incomplete vehicles require further approval when completed by the vehicle converter.

• The F-150 range has Type Approval for many territories, although the full range of vehicles shown in this manual are not necessarily released in all territories. Check with your local Ford National Sales Company representative.
• Significant changes to the vehicle may affect its legal compliance. Strict adherence to the original design intent for brakes, weight distribution, lighting, emissions, occupant safety, front and/or rear under-run compliance and hazardous materials compliance in particular is mandatory.

Alternative Type Approval
If significant changes are made to the vehicle the Body Builder / Vehicle Converter / Upfitter must negotiate with the relevant authority. Any changes to the vehicle operating conditions must be advised to the customer.
Legal Obligations and Liabilities
The Vehicle Converter should consult with its legal advisor on any questions concerning its legal obligations and liabilities.
Ford recommends that the Vehicle Converter and Ford Dealer must understand their individual and joint responsibilities in supplying a safe and compliant motor vehicle fitted with safe and compliant accessories.
General Product Safety Requirement
The Vehicle Converter shall ensure that any vehicle it places on the market complies with all local laws relating to the safe carriage of loads on public roads. The Vehicle Converter shall also ensure that any alteration it makes to a Ford vehicle or component does not reduce its compliance with local design rules.
The Vehicle Converter must provide sufficient Load Restraint tie down points or compartmentalized storage areas that enable the driver to safely carry loads that match the use criteria for which the body was designed. The Vehicle Converter shall not make any claims against any Ford entity resulting from or related to any of the following:

• Failure to comply with these Body Equipment Mounting directives, in particular warnings.
• Faulty design, production, installation, assembly or alteration not originally specified by Ford.
• Failure to comply with the basic fit for purpose principles inherent in the original product.

WARNINGS:
Do not exceed the gross vehicle mass, gross combination mass, axle ratings and trailer rating.
Do not change the tire size or load rating.
Do not modify the steering system.
Excessive heat can build up from the exhaust system, in particular from the catalytic converter. Ensure adequate heat shields are maintained. Maintain sufficient clearance to hot parts.
Do not modify or remove heat protection shields.
Do not route any electrical cables with the Anti-lock Brakes System and Traction Control System cables because of extraneous signal risk. It is generally not recommended to hang electrical cables off existing looms or pipes.
** Do not change original location or remove warning labels provided with the base vehicle in view to the driver. Ensure that labels in view to the driver remain in full view to the driver.
NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer.
Product Liability**
The Vehicle Converter should be aware of its potential liability for any product liability (whether for death, personal injury, or property damage) arising from or caused by any alteration to a Ford vehicle or component made by the Vehicle Converter or any of its agents. Ford shall not be liable for any such liability (except as provided by law).
The Vehicle Converter or equipment manufacturer is liable for the:

• Operational reliability and roadworthiness of the vehicle to its original intent. Operational reliability and roadworthiness of any component or conversion, not listed in original Ford documentation.
• Operational reliability and roadworthiness of the vehicle as a whole (for example the body changes and/or additional equipment must not have a negative effect on the driving,  braking or steering characteristics of the vehicle).
• Subsequent damage resulting from the conversion or attachment and installation of unique components, including unique electrical or electronic systems.
• Functional safety and freedom of movement of all moving parts (for example axles, springs, propeller shafts, steering mechanisms, brake and transmission linkage).
• Functional safety and freedom of the tested and approved flexibility of the body and integral chassis structure.

Restraints System
WARNINGS:
Modifications to the restraints system are not allowed. Airbags are explosive. For safe removal and storage during conversion follow the procedures in the Ford workshop manual or consult your local National Sales Company representative.
Do not alter, modify or relocate the airbag, sensor and modules of the restraints system or any of its components.
Attachments or modifications to the front end of the vehicle may affect the airbag deployment timing and result in unsafe deployment of safety devices.
Modifications to the side structure including doors, sills, B and C pillars might affect the side airbag deployment timing and result in unsafe deployment of safety devices.
Drilling and Welding
Drilling and welding of frames and body structures have to be conducted following the guidelines within this document.
Minimum Requirements for Brake system
Changes to the Antilock Brake System (ABS), Traction Control System (TCS) and Electronic Stability Program (ESP), Electronic Brake Booster (EBB) and
Driver Assistance Technologies are not permitted.
Road Safety
The respective instructions should be strictly observed to maintain operational and road safety of the vehicle.
Electromagnetic Compatibility (EMC)
WARNINGS:
Do not place objects or mount equipment on or near the airbag cover, on the side of the seatbacks (of the front seats), or in front seat areas that may come into contact with a deploying airbag. Failure to follow these instructions may increase the risk of personal injury in the event of a crash.
Do not fasten antenna cables to original vehicle wiring, fuel pipes and brake pipes.
** Keep antenna and power cables at least 4 in (10 cm) from any electronic modules and airbags.
NOTE:
We test and certify the vehicle to meet electromagnetic compatibility legislation.
It is the Vehicle Converter’s responsibility to make sure that any equipment a Vehicle Converter installs on the vehicle complies with applicable local legislation and other requirements.
Installation of some aftermarket electronic devices could degrade the performance of vehicle functions, which use radio frequency signals such as broadcast radio receiver, tire pressure monitoring system, push button start, Bluetooth connectivity or satellite navigation.
NOTE:**
Any radio frequency transmitter equipment in your vehicle (such as cellular telephones and amateur radio transmitters) must keep to the parameters in the following illustrations and table. We do not provide any other special provisions or conditions for installations or use.

Frequency BandMHz| Maximum Output Power Watts (Peak RMS)| Antenna Position
---|---|---
1-30| 50| l
50-54| 50| 2,3
68-88| 50| 2,3
142-176| 50| 2,3
380-512| 50| 2,3
806-870| 10| 2,3

Jacking
WARNINGS:
Ensure jack screwhead is adequately lubricated before use.
The jack should be used on level firm ground wherever possible.
Switch the ignition off and apply park brake fully before lifting vehicle.
It is recommended that the wheels of the vehicle be chocked, and that no person should remain in a vehicle that is being jacked.
No person should place any portion of their body under a vehicle that is supported by a jack.
Do not get under a vehicle that is supported by a jack.
**** The jack supplied with this vehicle is only intended for changing wheels. Do

not use the vehicle jack other than when you are changing a wheel in an emergency.
CAUTION:
Make sure that access to the spare wheel is maintained when converting the vehicle or relocating the spare wheel. If vehicle service body or mounted assembly affect the area surrounding the spare wheel, make sure sufficient clearance is left for successful lowering and raising of the spare wheel. Failure to adhere to this requirement may cause damage to the winching mechanism and insecure location of the spare wheel.
NOTE: When using the vehicle jack, refer to the owner guide for correct operating instructions.
The spare wheel winch is located above the spare wheel and can be accessed from the rear of the chassis frame.
The jack must be assembled and fixed appropriately to the body to ensure safety, durability and accessibility.
  CAUTION: Care must be taken to not damage the diesel fuel filter (if equipped) located under the floor in front of the transmission cross member. If care is not taken in placement of the jack or axle stands, damage to the fuel system could result. Lifting
WARNING: When lifting the vehicle with a two post lift for the removal of the engine/transmission or rear axle, make sure the vehicle is secured to the lift using vehicle retention straps to prevent tilting. Failure to follow these instructions may result in serious injury or death.
CAUTIONS:
When lifting the vehicle with a two post lift, vehicle lift arm adapters must be used under the lifting points.
When lifting the vehicle with a two post lift, the maximum kern weight must not be exceeded. It is important that only the correct lifting and support locations are used at all times.
Care must be taken to not damage the diesel fuel filter (if equipped) located under the floor in front of the transmission cross member. If care is not taken in placement of the lifting pads, damage to the fuel system could result.
Noise. Vibration and Harshness (NVH)
WARNING: Make sure that the modified vehicle complies with all relevant legal requirements.
Changes to the powertrain, engine, transmission, exhaust, air intake system or tires may influence the exterior noise emissions. Therefore the exterior noise level of the converted vehicle has to be verified.
The interior noise levels should not be deteriorated by the conversion. Reinforce panels and structures as appropriate to avoid vibrations. Consider the usage of sound deadening material on panels.

Reference Information

Ford Body Builder Advisory Service Contact
Contact Information:
Contact: FoA Customer Team
Phone: 73FORD or 13 36 73
E-Mail: foacustl@ford.com
Fax: 03 8301 2582
Postal Address: Ford Customer
Relationship Centre
Private Mail Bag 5
Campbellfield VIC 3061 73FORD or 13 36 73 foacustl@ford.com
Ford Service Publications
Ford Service Technical Resources (including wiring diagrams, repair manuals and diagnostic tool support) are available by subscription via the Motorcraft website: www.motorcraftservice.com

Model Lineup

6.5-ft Box
Drive| 4X4
Engine| 3.5L GTDI
GVMR| 3220| 3265
Payload (max)(1)| 769| 794
Base Kerb Weight (min)| Front| 1411| 1423
Rear| 1040| 1048
Total| 2451| 2471
Axle Rating| Front (max)| XLT| 1565| 1633
Lariat| 1633| 1701
Rear (max)| All| 1882
GCWR (MAX)| 7720| 7765

Foot Notes

1. Payload rating represents the maximum allowable weight of passengers, cargo and body equipment, and is reduced by optional equipment weight.
2. Gross Axle Weight Rating (GAWR) is determined by the rated capacity of the minimum component of the axle system  (axle, computer-selected springs, wheels, tires) of a specific vehicle. Front and rear GAWRs will, in all cases, sum to a number equal to or greater than the GVMR for the vehicle. Maximum loaded vehicle (including passengers, equipment and payload) cannot exceed the GVMR.

NOTE : Optional Equipment Weights  can be found in on the Ford BBAS website.
Navigate to: https://fordbbas.com under “Publications”, expand the “Vehicle Specifications” section and select the vehicle.

Dimensional Data

Super Crew

1130
L504| CAB TO PICKUP BOX (MINIMUM CLEARANCE)| 16
L551| BOX OVERALL LENGTH TO OPEN TAILGATE (MINIMUM)| 2365| 2665
L558| CL OF REAR AXLE TO CL OF FUEL FILLER DOOR| 504
L559| LENGTH OF OPEN TAILGATE| 537
CODE| DESCRIPTION| All
---|---|---
A130-1| WINDSHIELD ANGLE (DEGREES)| 56.5
H70l| FRONT BUMPER HEIGHT W / VALENCES| 399
Wll6| VEHICLE BODY WIDTH (MAX W/O MIRRORS)| 2030
Wl44| VEHICLE WIDTH| 2430
W702| FRONT BUMPER WIDTH| 1970

Style side Pickup Box PICKUP BOX

Rear Chassis Mounting
145-inch WB  Mounting holes:M12 nut plates

Note: All mounts are in the same plane/height (±1mm) Heights relative to mount datum (X)

Note: All mounts are in the same plane/height (±1mm)
157-inch WB Mounting holes:M12 nut plates****

Note: All mounts are in the same plane/height (±1mm) Heights relative to mount datum (X)

Note: All mounts are in the same plane/height ( ±1mm)

Tire & Wheel Data

Tire Data

Model Application| Tire Size / Description| Rim Width(in)| Section Width  (mm)| Static  Loaded
Radius (mm)| Diameter (mm)
---|---|---|---|---|---
Lariat| 275/60R20115T A/T
BSW| 9.| 274| 368| 835
XLT| 275/60R BSW20115T A/T| 9.| 282| 375| 835

Wheel Data

Model Application| Wheel Type / Description| Wheel Size (in.)| Wheel offset (mm)| No. of Studs| Bolt Circle (mm)| Max. Wheel Capacity
Load (Kg)
---|---|---|---|---|---|---
Lariat| Chrome like PVD
Aluminum| 20 x 8.5| 44| 6| 135| 1020
XLT| Machined Aluminum
with Painted Pockets| 20 x 8.5| 44| 6| 135| 945

Frontal Surface Area Worksheet

BELOW FRAME SHADED AREA= 1.050 m²
MIRROR SHADED AREA= 0.102 m² (BOTH MIRRORS)
TOTAL SHADED AREA= 1.152 m²
Seat Track & H-Point Data  Seat Dimensional Data

Seat Combinations| Seat Dimensions SgRP| Location
Driver| Passenger| A| B| C| D| E| F| G| H| X| Y
10-Way| 10-Way| 354| 98| 350| 339| 158| 413| 287| 276| 317| 311

Seat Track Angle to (Horizontal) Top of Frame = 2.5º
Add 10mm to dimension shown for Passenger Seat only.

Ford Driver Assist Technology

Ford Driver Assist Technology features that variously utilize a radar and/or camera system.
The radar and camera systems help provide Ford Driver Assist Technology features such as:

• Pre-Collision Assist with Automatic
• Emergency Braking (AEB)
• Forward Collision Warning
• Audible Lane Departure Warning
• Automatic High Beam
• Adaptive Cruise Control with Stop-andGo
• BLIS® (Blind Spot Information System) with cross-traffic alert and trailer-tow monitoring

Installed upfitter equipment should not infringe on the radar or camera view zones. The CAD files of the radar and camera view zones are available upon request via the Ford BBAS web site (www.fordbbas.com/contactus).
Consult the Order Guide for feature availability by vehicle model.

References

• Body Builder Advisory Service
• Body Builder Advisory Service
• Ford Owners Body Equipment Manual | Ford Australia
• Working...
• motorcraftservice.com/

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