SVE BULLETIN. QVM Bulletin: Q-186 Date: 29 March, F-Series Super Duty Chassis Cab 6.7L Diesel Urea Tank Relocation Kit

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1 Q-186 SVE BULLETIN SPECIAL ENGINEERING BODY BUILDERS ADVISORY SERVICE via website: (click "Contact Us") Toll-free: (877) QVM Bulletin: Q-186 Date: 29 March, F-Series Super Duty Chassis Cab 6.7L Diesel Urea Tank Relocation Kit To: All builders completing vehicles on the 2011 F-Series Super Duty Chassis Cabs. Models Affected 2011 F-Series Super Duty Chassis Cabs with 6.7L Diesel Engine and Aft-of Axle Fuel Tank Only Announcement: Ford Motor Company has designed and released a service kit to relocate the Urea Tank (Diesel Exhaust Fluid Tank) on Chassis Cab vehicles equipped with an aft-of axle-fuel tank only. The service kit will allow upfitters/dealers the option of relocating the Urea Tank from the factory design position (passenger side /outboard of rail) to a location on the driver's side/inboard of the frame rail where the mid-ship fuel tank would normally be packaged. Service Kit Availability: The Urea Tank Relocation Service Kit Part # BC3Z-5L223-A (Ref.: Engineering part number of kit is: BC34-5L223-AA) can be purchased from Ford Dealers, or from Ford Component Sales (Contact Donna Hoffman on , or dhoffm10@ford.com) Service Kit Instructions: See attached pages 1-9 Originator: BBAS Date Issued: 29 March 2010 Q-186 Date Revised: 29 March 2010

2 IMPORTANT: Please review the entire procedure before beginning. KIT - BC34-5L223-AA Part Number Description Quantity BC34-5J251-FA Front Adapter Bracket 1 BC34-5J251-GA Rear Adapter Bracket 1 BC34-5J249-PA Urea Heated Supply Line 1 W S439 M12 Hexagon Flange Bolt 4 W S440 M12 Hexagon Nut 4 W S439 M10 Bolt Plate 4 W S440 M10 Hexagon Nut 4 BC3T-14A655-HA Electrical Jumper Harness 1 AU5T-14E044-DA Offset Retainer for Harness 2 W S300 M12 Protective Caps 2 SK BC34-5L223-AA Instruction Sheet 1 RECOMMENDED TOOL LIST Item Tool 1 15mm socket/wrench 2 18mm socket/wrench 3 Side cutter pliers 4 Flashlight/drop light 5 Drill with 13mm or 1/2" drill bit (only required to open up 10mm frame holes) 6 Push-pin removal tool 7 Knife or similar sharp tool to remove electrical tape 8 Electrical tape DIESEL EXHAUST FLUID REFERENCE INFORMATION: Ford Motorcraft MSDS FIR No: Version Number US-US-3 Level 2 Release Date 10/14/2009 CAUTION: DIESEL EXHAUST FLUID MAY CAUSE SKIN IRRITATION. FOR SKIN CONTACT, FLUSH WITH WATER. DIESEL EXHAUST FLUID IS NOT FLAMMABLE. SK BC34-5L223-AA SHEET 1 OF 9

3 OVERVIEW OF AFT-OF -AXLE FUEL TANK EQUIPPED CHASSIS CAB MODELS WITH 6.7L DIESEL ENGINE (REFER TO FIGURE 1) CURRENT UREA TANK LOCATION AFT AXLE FUEL TANK FRONT OF UREA TANK TO BE MOVED TO THIS LOCATION FIGURE 1 NOTE: Frame crossmember locations will vary with wheel base. NOTE: Vehicles equipped with the spare tire in the temporary location may need to be removed and re-attached to support the tank relocation. SERVICE PROCEDURE: 1. Remove urea filler pipe and vent hose using quick connects located on urea tank. 2. Remove electrical connector from urea hydraulic line and disconnect the hydraulic line from urea tank supply module. The urea hydraulic line can now be completely removed from vehicle as a new line will be provided in the kit (refer to Figure 2). CAUTION: THE UREA HYDRAULIC LINE IS ELECTRICALLY HEATED AND CANNOT BE CUT OR SPLICED. CAUTION: USE CARE WHEN REMOVING THE HYDRAULIC LINE FROM THE SUPPLY MODULE TO PREVENT DAMAGING THE MODULE'S PLASTIC PORT. FRONT OF HYDRAULIC CONNECTION TO EXHAUST FIGURE 2 SK BC34-5L223-AA SHEET 2 OF 9

4 3. Remove 16-way electrical connector from frame and disconnect from vehicle harness (refer to Figure 3). FIGURE 3 4. Remove vehicle electrical harness from urea tank bracket retention (refer to Figure 4). FIGURE 4 CAUTION: THE UREA TANK MAY HAVE UP TO 6 GALLONS OF DIESEL EXHAUST FLUID (DEF) AND COULD BE SOME WHAT HEAVY. IF POSSIBLE, IT IS RECOMMENDED NOT TO DRAIN THE TANK DURING RELOCATION AND HAVE TWO PEOPLE ASSIST WITH REPOSITIONING THE UREA TANK. IF DRAINING IS REQUIRED, THE FLUID CANNOT BE REUSED. 5. Remove the two (2) bolts securing the tank strap to urea bracket (refer to Figure 5 ). FIGURE 5 SK BC34-5L223-AA SHEET 3 OF 9

5 6. Remove the two (2) straps while holding urea tank to ensure it doesn t fall off brackets (refer to Figure 6). Remove tank and set aside. FIGURE 6 7. Remove four (4) fasteners located inside the urea brackets. Three (3) will be nuts and one (1) will be a bolt, (refer to Figure 7). These need to be removed before brackets will come off the frame. Do not disassemble brackets any further. NOTE: The kit will provide two (2) new bolt plates for relocation. THREE (3) NUTS ONE (1) BOLT FIGURE 7 8. Locate the frame holes for the front and rear bracket mounting location. Install the adapter brackets to the inside of the frame using the supplied M12 bolts and nuts (90.0 ± 13.5 N m). Fasteners will be used on the side and underside of the frame (refer to Figure 8). NOTE: Electrical harness will need to be modified to support bracket installation (see BC3T re-work section on page 9). SK BC34-5L223-AA SHEET 4 OF 9

6 FRONT OF TWO (M12) BOLTS ON SIDE OF FRAME TWO (M12) BOLTS ON UNDERSIDE OF FRAME FIGURE 8 NOTE: The frame will have factory-supplied holes to mount the adapter brackets; however their size could be M10 or M12 depending on vehicle build dates. If M10 holes are supplied, you will need to up size the holes with a drill to accommodate the M12 bolt. CAUTION: IF THIS IS NEEDED, BE AWARE OF FUEL AND BRAKE LINES, AS WELL AS WIRING HARNESSES THAT MAY RESIDE NEAR THE HOLE INSIDE THE FRAME CHANNEL. YOU MAY HAVE TO MOVE OR SHIELD COMPONENTS AS NECESSARY TO PREVENT DAMAGE FROM THE DRILLING OPERATION. 11. After installing adapter brackets, install previously removed L-brackets using supplied bolt plates for front and rear brackets. Procedure is reversed for steps 5-7. Use four (4) M10 nuts to secure L-brackets, two (2) per side. Place tank on L-brackets, install the rear strap first to position the tank. Then install the forward strap and secure both straps with previously removed M10 fasteners (40 ± 6.0 N m). Verify straps are aligned with the tank and shield guides. (Refer to Figure 9). TWO (2) ADAPTER BRACKETS FRONT OF TWO (2) L-BRACKETS TWO (2) FRONT TANK STRAPS FIGURE 9 SK BC34-5L223-AA SHEET 6 OF 9

7 12. Attach heat-shielded end of urea hydraulic line to the exhaust s hydraulic connection (refer to figure 2). Then route the line along the designated path using tie straps to attach to inside the frame, rear cab cross member, electrical harness, and fuel lines as necessary (refer to Figure 10). ELECTRICAL JUMPER HARNESS (BC3T-14A665-HA) UREA HYDRAULIC LINE (BC34-5J249-PA) FRONT OF FIGURE Excess line should be wrapped in a coil in a horizontal plane to minimize sumps. Picture shows excess was routed around the supply module. Remember to plug in the heater connection when routing is completed (Refer to Figure 11). FIGURE 11 SK BC34-5L223-AA SHEET 6 OF 9

8 UREA FILLER PIPE AND VENT INSTALLATION 1. Cut the formed fill and vent hoses away from the filler cup and quick connects being careful not to damage the barb sections. Formed hoses can be discarded. 2. Using the filler kit supplied with the truck (clear plastic bag containing two (2) hoses, four (4) clamps, and black plastic housing), install the quick connects to the hoses and attach to the tank, (refer to Figure 12). 3. Determine routing that has: - No kinks - A minimum of 2 degree slope - No sumps (freezing of urea at 12F will prevent filling) - Sufficient hose length to the desired housing mounting location 4. Attach the hoses to the filler cup by sliding the fill and vent hoses over the barbs and retain using supplied spring hose clamps. 5. Attach the filler cup to the housing. 6. If previously drained, fill urea tank with approximately six (6) gallons of Ford approved Diesel Exhaust Fluid (refer to Figure 12). VENT HOSE CONNECTION FILL HOSE CONNECTION FIGURE 12 BC3T-14A655-HA INSTALLATION INSTRUCTIONS 1. Route and secure the 14A655 wire assembly to frame wiring harness using the supplied tie straps. Trim excess strap (Refer to figure 13). 2. Begin routing from the right hand frame rail. Secure connector and 14A655 wire assembly retainer to the right hand frame side rail. SK BC34-5L223-AA SHEET 7 OF 9

9 FRONT OF FIGURE Route wire assembly up and over right hand rear cab mount and along crossmember (refer to Figure 14). FIGURE Bundle and secure wiring with tie straps. Trim excess strap. Any excess wire should be secured along the right frame rail (refer to Figure 15). FRONT OF FIGURE 15 SK BC34-5L223-AA SHEET 8 OF 9

10 BC3T REAR LAMP WIRING ASSEMBLY REWORK 1. Replace the two (2) existing wiring assembly retainers on the rear lamp wiring with the two (2) provided AU5T-14E044-DA retainers (refer to Figure 16). FIGURE Secure retainers to harness with tape and reinstall to frame (refer to Figure 17). FIGURE Place the two (2) W S300 M12 protective caps over urea tank bracket attachment screws (refer to Figure 18). 4. Make connection to the urea tank and secure it to the tank bracket (refer to Figure 18). CONNECTION TO UREA TANK FIGURE Start vehicle and perform visible inspection for any hydraulic leaks. Check the instrument cluster for warning lights or messages related to the Diesel Exhaust Fluid System. If extensive troubleshooting is required, contact Ford Body Builder Advisory Service at SK BC34-5L223-AA SHEET 9 OF 9