Documente Academic
Documente Profesional
Documente Cultură
General Information 2
E-Series Cutaway 3
E-Series Stripped Chassis 4
Super Duty F-Series 5-7
Transit 8-10
INFORMATION SECOND UNIT BODY STRUCTURES UNDERBODY HEAT MANAGEMENT The subsequent stage manufacturer should also
The following recommendations are intended to assist The structural design and materials used in the 1. Underbody longitudinal or lateral air movement consider the following situations, which may have an
in the design of second unit bodies and body mounting construction of second unit bodies must be sufficient to should not be restricted. Frame spacers designed by adverse effect on heat management.
systems that will control second unit body movement help control collapse of the body and prevent the intermediate and final stage manufacturer should ● Poor vehicle service or lack of maintenance
with respect to the Ford supplied chassis when tested disengagement from the chassis when tested in provide for adequate airflow over the frame.
to the procedures specified in F/CMVSS 126, 204(1), accordance with the specifications of F/CMVSS 126, 2. No portion of the floor pan should drop below the ● Deviation from a Ford recommended antifreeze
208, 212(2), 214(2), 219(2), and 301(2). These 204(1), 208, 212(2), 214(2), 219(2), and 301(2). Steel or body sills, nor should the underbody structure drop coolant
recommendations are based on testing and analyses aluminum structures are recommended, however, wood below the top surfaces of the number 3 and 4
performed by Ford Motor Company. or composite materials may require additional crossmembers. These conditions can result in
● Exceeding Ford GVW and GCW ratings
Second Unit Bodies (SUB) and their body mounting reinforcements to provide the structural integrity reduced airflow, pinched fuel lines or vapor hoses ● Malfunctioning systems such as exhaust or engine
systems may take many forms, and the following required for actual crash testing. SUB structures should which can raise the temperature of underbody
recommendations cannot cover all the possibilities. not exceed beyond (overhang) the end of the chassis components and increase fuel system pressure. ● Altering, changing, removing Ford engine cooling
Strict adherence to these recommendations will not (frame side members). 3. Any interior floor underlayment or insulation in the fan and shroud
ensure that the completed vehicle will comply with near vicinity of the exhaust system, without benefit of
F/CMVSS 126, 204(1), 208, 212(2), 214(2), 219(2), or SECOND UNIT BODY FUEL SYSTEM COMPONENTS ● Blocked radiator grille area (spare tire, bicycles,
the Ford provided heat shields, must be capable of
301(2). The final stage manufacturer who installs a SUB floor and bulkhead structures must accommodate withstanding 371°C [700°F] (482°C [700°F] in close etc.)
second unit body on the chassis is responsible for the Ford fuel fill system and suggested design proximity to the catalyst) during normal operating
compliance to the above mentioned regulations.
● Use of throttle kickers
clearances. Fill neck locations and all F/CMVSS 301(2) conditions. Additionally, any underchassis-mounted
Accordingly, Ford Motor Company cannot represent compliance representations for Super Duty F-Series components within 101.6 mm [4 in] of the exhaust ● Addition of aftermarket PTO system
that these recommendations are appropriate for every and E-Series vehicles are in the Statements of system must be compatible with these temperatures.
specific application of a second unit body, the body Conformity section of the Incomplete Vehicle Manual. 4. Second unit body exterior panels, tool boxes,
mounting system, or act of a subsequent stage See additional Fuel System Design Recommendations. running boards, structures, or skirting that extend
manufacturer. below the bottom of the frame, may affect underbody
To verify compliance of a particular second unit body SECOND UNIT BODY ELECTRICAL temperatures. The final stage manufacturer should
and selected body mounting system with F/CMVSS Some electrical power sources are identified in the verify that underbody temperatures of the completed
204(1), 208(2), 212(3), 214(3)(4), 219(3), and 301(3), the Design Recommendations and the F/CMVSS 108 vehicle are compatible with all vehicle’s components
testing of a representative vehicle to the applicable compliance representations in the Incomplete Vehicle when under conditions that consider the projected
procedures of the above regulations is recommended. Manual. For wiring diagrams and additional information vehicle duty cycle and vehicle loading.
Questions regarding compliance with F/CMVSS see Electrical Wiring pages in the Electrical Section. 5. Full-width mudflaps should not be installed, as they
regulations should be directed to your legal counsel, restrict airflow under the vehicle and can also
the National Highway Traffic Safety Administration, or HEADLIGHT ALIGNMENT increase underbody temperatures.
Transport Canada.
Headlight initial aim is set at the assembly plant, but 6. Added structure or equipment should not restrict air
may not be correct for your final vehicle configuration. circulation in the engine compartment/underbody.
Therefore, headlight aim verification after installation of 7. Added body vents, especially powered vents, should
the SUB is the responsibility of the final stage be located away from the fuel filler and venting areas
manufacturer, and should be part of the completed and exhaust to avoid fuel fumes and vapors entering
vehicle sign-off. the interior of the vehicle.
8. Use of wood in construction should be eliminated
where at all possible. If used, wood should be
adequately protected from moisture and heat.
Shields should be added if wood is installed near
exhaust components.
NOTES —
(1) For vehicles with a GVWR of 10,000 lb or less and
an unloaded vehicle weight of 5500 lb or less.
(2) Applicable to vehicles with a GVWR of 10,000 lb
or less.
E-SERIES SUPER DUTY CUTAWAY SUB MOUNTING NON-FORD SPACERS NO SPACERS NOTES
SYSTEM Vehicles not equipped with the Ford optional spacers If the final stage manufacturer chooses to attach the 4470 mm [176 in] wheelbase vehicles equipped with a
have 34.8 mm [1.37 in] diameter holes on the upper SUB (or other components) to the frame by bolting or 55 gallon fuel tank will require a 457 mm [18.00 in]
FORD OPTIONAL SPACERS flange of the frame sidemembers for body to frame welding, the following restrictions are to be followed: minimum frame extension to provide for an adequate
Ford provides optional SUB mounting spacers which isolators. The density/durometer, size and quantity of 1. The frame rail flanges, including the flange bend departure angle.
will isolate the SUB from the frame. The SUB should be these isolators should be based on the SUB weight radius, must not be drilled or welded upon. Also, The attachment of the SUB to the cutaway body should
attached to these spacers using all the provided holes plus the projected payload of the completed vehicle, flanges may not be cut/trimmed to provide consider the following:
in the spacer with a suggested minimum 7/16-14 UNC within the limits of the GAWRs and GVWR, as clearance to added hardware or structure. 1. Blind installation of self-expanding nut type
grade 8 fastener. These fasteners should be directed determined by the final stage manufacturer.
2. When bolting the SUB (or other components) to fasteners can be located in the zone as defined in
away from any fuel system component or should not the frame, follow the guidelines in the Pickup Box the figure on this page, and should allow for
extend more than 25.4 mm [1.00 in] below the spacer Delete section. functional expansion, and be equally spaced. The
flange. The rubber isolators on the spacers are capable body edge flange may also be used for fasteners
Note that hard mounting of the SUB to the frame and to
of 19.0 mm [0.75 in] movement from a static (design) provided the center of the required hole is 1.5
the cutaway body may result in NVH and cutaway body
position, which is the same for the isolators that mount times the hole diameter from the edge of the
durability issues.
the cutaway body to frame. This will minimize squeaks, panel. These recommendations apply to both B-
rattles and water or air leaks at the mounting surface of pillar attachment.
the SUB, to the cutaway body. The Ford optional
2. Removal of the access panel and fasteners at the
spacers will accommodate the recommended fuel fill
lower area of the B-pillar will allow for flush
neck installation and a recommended 101.6 mm [4.00
mounting of the SUB. This opening should be
in] minimum clearance between the frame and the
completely covered and sealed from obvious
bottom of the SUB (except at the rear axle kick-up
climatic conditions.
area).
3. Roof attachments should be equally spaced and
are permitted on the flange provided. The center
of the required holes should be 1.5 times the hole
diameter from the edge of the flange.
4. Floor attachments should be equally spaced and
are permitted on the flange provided. The center
of the required holes should be 1.5 times the hole
diameter from the edge of the panel.
5. Washers or doublers should be considered to
increase the bearing surface under fasteners to
BLIND FASTENERS increase joint integrity and to decrease sheet
INSTALLATION metal fatigue, squeaks, and rattles.
ZONE 6. Gaskets or sealers installed between the cutaway
body and the SUB should consider the
displacement and stabilization of such materials
when clamped, and the effect on joint integrity.
50.0
[1.97]
FRONT OF
VEHICLE 45.0 10.0
[1.77] [0.40] ACCESS PANELS
REAR BOLSTER
FRONT TIE BOLT
BOLSTER BAR ATTACHMENT
RADIATOR COWL
SUPPORT STRUCTURE
TIE
BAR
A B C
SUPER DUTY F-SERIES SECOND UNIT BODY (SUB) DETAILS OF THE SECOND UNIT BODY MOUNTING SUB mounting instructions for a SUB weight over NOTE: The following items are important factors in the
MOUNTING TECHNIQUES FOR PICKUP BOX TECHNIQUES 3960 kg [1800 lb] and a 56" CA: performance of the system:
DELETE (WIDE FRAME) The following SUB mounting design recommendations ● Use same as Technique #1 except with addition of U- ● The spacer should be secured in such a manner as
The intent of the illustrations shown on the following two are methods of attachment intended to minimize SUB bolts as shown in Figure D. to maintain retention during installation or during
pages is to offer an expanded range of Second Unit movement under crash situations. The following items operational use and should have a slight taper which
Body (SUB) mounting design recommendations for are important factors in the performance of the system: SUB mounting instructions for a SUB with a 60", starts at the front of the SUB frame. See Figures D,
Super Duty F-Series Pickup Box Delete trucks with a 1. The forward most surface of the SUB is located at 84", 108", or 120" CA: E, and F.
1422 mm [56 in] Cab to Axle (CA) design. least 76.2 mm [3.0 in] behind the rearmost surface ● It is recommended that the front shear plate mounting
● Front shear plates should be angled forward
of the cab. Refer to the Statements of Conformity approximately 45 to 60 degrees from the horizontal.
holes, as provided on each chassis, be used. Use the
SUB Mounting Techniques #1 and #2 for 56" CA for F/CMVSS 212(1), 219(1), and F/CMVSS 301(1) in Front shear plates should be a sufficient distance
same front and rear shear plate attachment as
with SUB weight 1800 lb or less: the Incomplete Vehicle Manual. from the front of the SUB to allow for frame flexing,
Technique #1 or #2 with a 5/8" diameter U-bolt
These SUB mountings were tested by Ford Motor 2. Spacers between the frame and SUB must provide i.e., front shear plates should be placed behind the
spaced every 24 to 36 inches. See Figure E.
Company and found to be capable of complying with adequate clearance to the fuel fill system on wide tapered section of the spacer.
● When U-bolts are used, vertical spacers must be
● Use 5/8" diameter, grade 8 bolts, nuts, and washers
F/CMVSS requirements. The sketches in Figures A and frame pickup box delete models to allow a proper between the upper and lower frame flanges at each
B on the following page depict the recommended SUB fuel filler pipe installation. Refer to the Statement of that attach the shear plates to the OEM vehicle and
U-bolt to prevent collapse of the flanges. See Figure
mounting techniques. Conformity for F/CMVSS 301(1) of the Incomplete SUB frame.
F.
Vehicle Manual and the Design Recommendations ● 60-65 ft-lb torque for the 5/8" diameter, grade 8 bolts,
SUB Mounting Technique #3 for 56" CA with SUB for fuel fill systems. nuts, and washers.
weight 1800 lb or less: ● Direct the threaded end of the bolts away from any
The third mount scheme is a top bolted mounting SUB mounting instructions for a SUB weight of fuel, brake or electrical system components.
technique. This top bolted SUB mounting is 3960 kg [1800 lb] or less and a 56" CA: ● U-bolts or attaching hardware should not contact fuel,
● Technique #3
Pickup box attachment: use eight 5/8" diameter,
grade 8 flange nuts and bolts that utilize the existing
pickup box holes in the top frame flanges. See Figure
C.
(Cont'd next page)
Ford BBAS Website
Body Builders Layout Book
6 SECOND UNIT BODY MOUNTING 2019
SECOND UNIT BODY SUPER DUTY F-SERIES (Cont'd) MODEL YEAR
BACK OF CAB
BACK OF CAB
SUB CROSS–SILL
SUB CROSS–SILL
FUEL FILLER CLEARANCE FRAME RAILS
FRAME RAILS
OEM FRAME
OEM FRAME
FRONT SHEAR
PLATE REAR BUMPER
FRONT
VIEW B REAR BUMPER BRACKET
SHEAR VIEW C
BRACKET & SHEAR
VIEW A PLATE SPACER – FRAME TO SUB
& SHEAR PLATE
SUB LONGITUDINAL
PLATE
FRAME
SUB LONGITUDINAL FRAME FRONT SHEAR PLATE SUB LONGITUDINAL FRAME REAR BRACKET SUB CROSS–SILL FRAME RAILS
MAT’L 3/8” HRLC STEEL MAT’L 3/8” HRLC STEEL
FRONT SHEAR PLATE SUB CROSS–SILL FRAME RAILS
SPACER
MAT’L 3/8” HRLC STEEL
BUMPER
OEM FRAME ATTACHMENT TAPERED SPACER
SPACER
REAR
BRACKET
OEM
FRAME BUMPER
ATTACHMENT
DRAWING DEPICTS SUB LONGITUDINAL FRAME WITH ONE DRAWING DEPICTS SUB LONGITUDINAL FRAME WITH ONE DRAWING DEPICTS SUB CROSS–SILL DRAWING DEPICTS SUB CROSS–SILL FRAME WITH TWO
5/8” DIA. BOLT AND 1/4” WELD BEAD AROUND THE 5/8” DIA. BOLT AND 1/4” WELD BEAD AROUND THE FRAME WITH TWO 5/8” DIA. BOLTS 5/8” DIA. BOLTS ATTACHING THE REAR BRACKET
PERIMETER OF THE SHEAR PLATE. PERIMETER OF THE SHEAR PLATE TO SUBFRAME, THREE 5/8” DIA. GRADE 8 BOLTS/
NUTS/WASHERS/ARE NEEDED TO ATTACH THE REAR
IF THE SHEAR PLATE IS NOT WELDED ON THE SUB LONGITUDINAL IF REAR BRACKET AND SUB FRAME ARE NOT WELDED BRACKET TO THE OEM FRAME BOLTS ATTACHING THE REAR BRACKET
FRAME, TWO 5/8” DIA. BOLTS WOULD BE NECESSARY TWO 5/8” DIA. GRADE 8 BOLTS WILL BE
TO ATTACH THE SHEAR PLATE TO THE LONGITUDINAL FRAME. NECESSARY TO ATTACH REAR BRACKET TO SUB FRAME.
THREE 5/8” DIA. BOLTS/NUTS/WASHERS ARE NEEDED TO
ATTACH THE REAR BRACKET TO OEM FRAME.
VIEW A VIEW C VIEW D
VIEW B LEFT FRONT SHEAR PLATE
LEFT FRONT SHEAR PLATE LEFT REAR BRACKET (SUB CROSS–SILL FRAME)
LEFT REAR BRACKET (SUB LONGITUDINAL FRAME) (SUB CROSS–SILL FRAME)
(SUB LONGITUDINAL FRAME) RIGHT REAR BRACKET IS A MIRROR IMAGE.
RIGHT REAR BRACKET IS A MIRROR IMAGE. RIGHT SHEAR PLATE IS A MIRROR IMAGE
RIGHT SHEAR PLATE IS A MIRROR IMAGE.
RECOMMENDED SHEAR PLATE ATTACHMENT FOR SECOND UNIT BODIES WEIGHING 1800 LBS OR LESS WITH A 56”CA RECOMMENDED SHEAR PLATE ATTACHMENT FOR SECOND UNIT BODIES WEIGHING 1800 LBS OR LESS WITH A 56”CA
FIGURE A - SUPER DUTY F-SERIES SUB MOUNTING TECHNIQUE #1 FIGURE B - SUPER DUTY F-SERIES SUB MOUNTING TECHNIQUE #2
BACK OF CAB
U–BOLTS
Z
Z 5/8” AS NECESSARY
LENGTH GRADE 8
Same front and rear shear plate attachment as SUB mounting techniques #1 and #2 with a U-Bolt spaced
every 24 to 36 inches. Torque 5/8” U-bolts to 60-65 ft-lb. Do not notch the frame flanges to make
the U-bolts fit. Place a spacer in between the OEM frame flanges to provide proper U-bolt torque.
FIGURE E - SUPER DUTY F-SERIES SUB MOUNTING FOR 60”, 84”, AND 120” CA CHASSIS CABS
BACK OF CAB
U–BOLTS
FRAME SPACER FRAME
FRAME
SIDEMEMBER SPACER
TYPICAL INSTALLATION
(VIEW SHOWING INBOARD SIDE OF RAIL)
Where wrap around body attachments (such as U-Bolts) are used, the frame sidemembers must have
flange reinforcement spacers to avoid flange damage when full torque is applied to attaching bolts.
Spacers are recommended and must be cut out to clear brake lines, fuel lines, wiring, etc. If metal
spacers are used, no welding to frame sidemembers is permitted.
OEM FRAME REAR Tapered spacers between vocational-body sill and frame sidemember flanges are recommended.
SPACER BUMPER (see sketch for typical installations).
SUB BRACKET Periodic checking of body attachments for torque retention is highly recommended.
LONGITUDINAL & SHEAR
PLATE A minimum of one set of shear plates per side is recommended. Also, one set of side shift plates
FRAME
should be attached to vocational-body sills per side.
FIGURE D - SUPER DUTY F-SERIES SUB MOUNTING TECHNIQUE #4 FIGURE F - SUPER DUTY F-SERIES SUB FRAME SPACER FOR U-BOLT
TRANSIT CHASSIS CAB & CUTAWAY SECOND UNIT BODY FRAME RAIL MOUNTING HOLES
94.4
[3.72]
12.8
8 HOLES [.504] DIA.
TBD BY
UPFITTER 1524
*GREATER THAN EXTENSION
[60.0]
REQUIRES ADDITIONAL CROSSMEMBER
REAR WHEEL
FRAME
EXTENSION
[12.16]
[12.16]
[24.24]
[24.24]
308.8
308.8
615.6
615.6
[32.94]
[32.94]
836.8
836.8
1436.8 1441.3 1443.0 1441.3 1436.8
1408.0 [56.57] [56.74] [56.81] [56.74] [56.57] 1408.0
[55.43] [55.43]
1552.6
[34.17]
[34.17]
868.0
868.0
[61.1]
1039.4 1039.4
[40.92] [40.92]
CENTERLINE OF VEHICLE
NON-THREADED NUTPLATE [15]
[34.49]
[34.49]
876.0
876.0
M8 X 1.25
647.4 647.4
[25.49] [25.49]
[34.49]
[34.49]
876.0
876.0
277.4 277.4
[10.92] [10.92]
TOP OF UNDERBODY
0 0
92.7 92.7
[3.65] [3.65]
[34.49]
[34.49]
876.0
876.0
0
NOTE — [ ] DIMENSIONS ARE INCHES.