What's New Book 2012 MY

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1 DRIVE ONE What's New Book 2012 MY Drive Green Commercial Vehicle Special Vehicle Engineering June 2011

2 Page No. TABLE OF CONTENTS 2012 MY What's New Book Subject 2 Table of Contents MY Ford Truck What s New Book Body Builder Quality Programs and Assembly Plant Job #1 Timing E-Series E 150/ E250/ E350/ E450 Wagon/ Van/ Cutaway/ Stripped Chassis Major Product Features 9-11 Transit Connect Major Product Features F 250/ E350/ F450/ F550 Super Duty 2010 MY Major Product Features F53 & F59 Commercial Stripped Chassis Major Product Features F 650/ F750 Major Product Features F 150 Major Product Features 24 Alternative Fuel Buyers Guide 25 Important Phone Numbers and Web Sites 26 Obtaining Publications 2

3 2012 MY Ford Truck What s New Book The purpose of this book is to provide some advance insight into 2012 model year Ford Truck product features that may assist final stage manufacturers and vehicle alteration companies in preparing their production process. This book is for reference only, reflecting information available as of June 2011 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. FOR ADDITIONAL INFORMATION VISIT: Truck Body Builder Advisory Service Website ( Bulletins: Hot Off The Press: Publications: Body Builder Layout Book: Quality Program Guidelines: Incomplete Vehicle Manuals: Support Contacts: Other: Lists links to the latest Bulletins for Ford Truck Quality Programs Lists links to latest up-to-date publications available to body builders Provides access to Body Builders Layout Book Lists links to Ford Truck Quality Program Guidelines for final stage manufacturers and vehicle alterers Lists links to model years IVM s Lists frequently requested phone and fax numbers Links and Frequently Asked Questions (FAQ) 2008 Ford Motor Company. 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. 3

4 Body Builder Quality Programs Responsible for qualifying the engineering process control capability of final stage manufacturers under these Ford Truck 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 Commercial Vehicle Engineering. TRUCK BODY BUILDER ADVISORY SERVICE (BBAS) Provides technical assistance for truck body builders Phone: (877) Web Site: SPECIAL VEHICLE ENGINEERING & QUALITY PROGRAMS Responsible for qualifying the engineering process control capability of the final stage manufactures under these Ford Truck Quality Programs Ambulance Quality Program Motor home & Transit Bus Quality Program Conversion Van Quality Program Series Quality Program Adaptive Mobility Quality Program Ship Thru Quality Program Alternative Fuels Program Assembly Plant Job #1 Timing Model Year - Vehicles Assembly Plant MP1/Job # MY E Series Ohio Assembly Plant 7/25/ MY F 150 Dearborn Truck Plant & Kansas City Assy Plant 10/17/ /03/ MY F 250/ F350/ F450/ F550 Super Duty Kentucky Truck Plant 6/27/ MY F53/ 59 Commercial Stripped Chassis Detroit Chassis Plant 7/18/ MY F650/ F750 Medium Truck Escobedo, Mexico 3/29/ MY Transit Connect Kocaeli, Turkey 7/18/ Ford Motor Company. 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. 4

5 2012 MY E-Series (E150/ E250/ E350/ E450) WAGON/ VAN/ CUTAWAY/ STRIPPED CHASSIS MAJOR PRODUCT FEATURES E-350 DRW Cutaway The new 2012 MY Ford E -Series builds on its popularity in the full size van segment, where it has been the top of the tool chain since It's truly an American icon for more than 50-years. The E-Series is both the preferred tool box for so many applications as well as the people-moving vehicle and the reason is because it s available in a myriad of poplular configurations and ease of modificatio with body builder - upfitters. NEW FEATURES AND BENEFITS SUMMARY Feature Benefit s School Bus Prep Pkg E-350 SRW School Bus Prep Package 10,050 lbs GVWR 138 wheelbase Dual Battery Option Optional Ash Cup Dual-battery option replace existing auxiliary battery option (all models) Added an optional ash cup on all E-Series, with consoles B Pillar Trim Added B-pillar trim option (A1HAB) in Flint only, on cutaways New Audio Input Jack Audio input jack on AM/ FM radio standard 5

6 2011 MY E-Series Mid Year Actions 5.4L gas engine Ambulance Prep Package for Gulf Coast Country s Gulf Coast (GCC) Vans only New Gas Ambulance Prep Pkg Rear GAWR increased to 9600 lbs on E450 Cutaway only (Q-197) GCWR increased to 22K on E450 Cutaway w/ 6.8L engine (Q-193) E450 SRW Cutaway Rear Aux Heater/ AC available on RV Vans as a regular production option Wheel lug wrench deleted on Cutaways and Stripped Chassis without spare tire option 4 key option (versus 2) on Cutaways, Vans and Wagons Extra fuel/ vapor line clamps deleted from incomplete fuel kit (Re-use existing clams (Q-205) E250 SRW Cargo Van New Aluminum wheel appearance/ design (Differentiator - Beveled openings) New Aluminum Wheel 6

7 2012 MY E-Series New Option & Features E-350 SRW School Bus Prep Package 10,050 lbs GVWR 138 wheelbase (6,084 lbs rear GAWR) New School Bus Prep Package Dual-battery option replace existing auxiliary battery option (all models) Added an optional ash cup on all E-Series, with consoles (was standard) Added B-pillar trim option (A1HAB) in Flint only, on cutaways Cargo Van Audio input jack on AM / FM radio standard 7

8 2012 MY E-Series New Options & Features Seat material change to the front driver side and passenger side seats in the area noted only Calvin replaced with Quantum Front Drivers Seat Shon Seat material change to rear passenger seats in the area noted only. Calvin replaced with Quantum 3rd Row Rear Passenger Seat Shown All rear row seats affected 8

9 2012 MY Transit Connect MAJOR PRODUCT FEATURES Transit Connect The 2012 MY Transit Connect is the only purpose-built light commercial cargo van designed to not only meet but to exceed the needs of small businesses. From dual purpose functionality with Van and Wagon configurations to the optional Ford Work Solutions Crew Chief package designed for multi-unit fleets, Transit Connect features provide direct benefits to small companies. Even the wagon s 60/40 bench folds forward, storing neatly behind the front seats to allow for increased storage. The Transit Connect is defined as Versatile, Capable and Affordable. The Transit Connect has been tested to commercial vehicle requirements of 150,000 miles to ensure it can withstand the punishment of commercial applications. It drives like a Car, works like a Van and is engineered to be as tough as a Truck. NEW FEATURES AND BENEFITS SUMMARY AdvanceTrac AdvanceTrac with RSC TM standard on all models SYNC Aluminum Wheel SYNC enabled AM/FM single CD w/ audio input jack (late availability) Aluminum wheel option (late availability) Sun-Visor Slide-on rod sun-visor Enhanced Speaker System Enhanced audio system is standard on both AM/FM w/ single CD and AM/FM radios 9

10 2012 MY Transit Connect New Options & Features AdvanceTrac with RSC TM now standard on all models New slide-on rod sun-visor Three new wagon exterior colors: Winter Blue, Noisette and Dark Micastone Additional cup holder (late availability) Optional SYNC enabled AM/FM single CD w/ audio input jack (late availability) Standard AM/FM w/ audio input jack (late availability) Enhanced audio system is standard on both AM/FM w/ single CD and AM/FM radios Aluminum wheel option (late availability) Fuel economy is now 21/ 27 mpg w/ 23 mpg avg on Van s & Wagon s Drive Green 10

11 2012 MY Transit Connect New Feature Taxi - seats now available in Vinyl or Cloth (Vinyl Seats Shown) Taxi - fuel economy is now 22/ 27 mpg w/ 24 mpg avg Leg Room 11

12 2012 MY F-Series Super Duty MAJOR PRODUCT FEATURES F550 XL Super Duty Chassis Cab The new 2012 MY Ford F Series Super Duty continues to reinforces the BOLD Built Ford Tough image of the F Series and expands its availability to meet the needs of a multitude of commercial vocations, as well as personal use. In short the Ford F Series Super Duty is a game changer not only does it combines all the attributes of power, capability and breadth of product choices which are enhanced by new customer features, it s more fuel efficient. NEW FEATURES AND BENEFITS SUMMARY Feature Benefit s CNG/ LPG Engines Prep Options Adjustable headrest TPMS Fleet Delete Optional payload downgrade Heavy Service Package 6.2L 3V Gaseous Engine 4 way adjustable headrest F350 SRW fleet Tire Pressure Monitoring System (TMPS) delete option on over 10,000 lbs GVWR F250 pickups have optional fixed 9,900 lbs GVWR payload downgrade packages Heavy Service package for Pickup Box Delete GVWR Chassis Cab F350 SRW Chassis Cab GVWR 10,200/ 11,500 lbs standard 12

13 2012 MY F-Series Super Duty New Features and Mid Year Actions 2011 MY Mid Year Action Opened availability of F350 SRW Chassis Cab 10,000 lbs GVWR and below (Released trailer tow hitch with FCSD to comply with FMVSS 301 (Q-203) Interior: Steering wheel with 3 button message center 4-way adjustable Headrest - trim level dependant Exterior: Body side molding deleted on Regular Cabs Expanded usage of mud flaps on the F350 Chassis Cabs SYNC functionality powered by Microsoft Chassis: F350 SRW Chassis Cab GVWR 10,200/ 11,500 lbs standard and (9800/10,000 lbs payload down grade options available) F350 SRW pick up 4x4 137 Wheel Base 6.2L gas engine and 18 Wheels/Tires has 11,100 lbs GVWR std with Camper or Camper Snow Plow prep package (same configuration w/o equals 11,000 lbs GVWR) F250 Pickups have Optional Fixed 9,900 lbs GVWR Payload Downgrade Package 6.2L/6.7L engines F350 fleet delete option on TPMS on F350 SRW over 10,000 GVWR Heavy Service package for F350 Pickup Box Delete (63R) F350 (heavy service front springs, rear stabilizer bar/ aux springs) was F250 only Powertrain: 6.2L 3V Gaseous Fuel Engine Prep Package with Bi-Fuel manifold (Includes harden valves and valve seats). 13

14 New 2012 MY F53/ F59 Motorhome Stripped Chassis MAJOR PRODUCT FEATURES F59 Commercial Stripped Chassis The 2012 MY Ford F53 is the #1 Selling Class A Motorhome chassis. Its Triton V10 gasoline engine, 5-speed TorqShift transmission, a tough ladder-type frame and wide range of wheelbase offerings make this a popular choice among RV ers at all levels of the market. These features are further enhanced by an 8000 lbs front GAWR on the 22,000 lbs GVWR chassis, revised rear axle ratios on the 16K and 18K chassis for improved fuel economy and increased fuel capacity from 75 to 80 gallons on all motorhome chassis. NEW FEATURES AND BENEFITS SUMMARY Feature Benefit s New Pull-out Ramp New Gas Engine Introduction of a new optional integrated 10-foot Pullout Ramp Package, 208 F59 Only 6.8L 3V Gaseous Prep Engine New ABS Program 3 Channel ABS Program 14

15 2012 MY F53/ F59 - New Features & Mid Year Actions 2011MY Mid year action New 6.8L 3V Gaseous Prep Package 2012 MY New Feature: 2012 MY Introduction of new optional integrated 10-foot Pull-out Ramp Package, 208 wheelbase F59 only New 10-foot ramp, integrated between the rear frame rails 15

16 2012 MY F53/ F59 - Trailer Brake Controller New Trailer Brake Controller Wire Take Out Location: 2011 MY (Q 206) To improve customer access and service to the connector it has been relocated to the left hand side of the steering column support. The end-of-frame trailer wiring harness is carryover and is not affected. See Figure 2. Original Trailer Brake Controller Wire Take Out Location: MY Chassis the trailer brake controller connector is located behind the instrument cluster making it difficult to reach after the installation of the instrument panel. See Figure 1 New 3 Channel ABS Module available on 16,000 19,000 GVWR Active front wheel speed senor s. The rear wheel sensor signal comes from the transmission via the output-shaft-sensors 16

17 2012 MY F53/ F59 Motorhome Stripped Chassis F59 Stripped Chassis New Product Specification Description New Model Year - Specification Original Model Year - Specification Wheelbase Availability (2Q 2011) (3Q 2011) (Job #1 2012) 2010 MY 2010 MY 2010 MY GVWR 19,500 lbs 16,000 lbs 19,500 lbs 16,000 lbs 19,500 lbs 22,000 lbs GCWR 26,000 lbs 23,000 lbs 26,000 lbs 26,000 lbs 26,000 lbs 26,000 lbs Max. Trailer Capacity 6,500 lbs 7,000 lbs 6,500 lbs 10,000 lbs 6,500 lbs 4,000 lbs Front GAWR 7,000 lbs 6,500 lbs 7,000 lbs 6,000 lbs 7,000 lbs 8,000 lbs Rear GAWR 13,500 lbs 11,000 lbs 13,500 lbs 11,000 lbs 13,500 lbs 15,000 lbs Curb Weight (approx.) 5,695 lbs 5,635 lbs 6,005 lbs 5,585 lbs 5,665 lbs 6,005 lbs 17

18 2012 MY F650/ F750 MAJOR PRODUCT FEATURES F650 F650/F750 Medium Truck The 2012 MY Ford F-Series Super Duty reinforces the Built Ford Tough image of the F-Series vehicles and expands its capability to meet and exceed the needs of a multitude of commercial vocations, as well as personal use. Ford F-Series Super Duty combines the attributes of power, capability, and toughness that is second to none. Feature Benefit s NEW FEATURES AND BENEFITS SUMMARY New 6.8L 3V Gas Engine New Transmission Fuel Tank Location 6.8L 3V on F650 models only late availability Optional 6.8L 3V gaseous fuel prep package New 6 speed 6R140 trans (with and without optional stationary PTO prep package) Outside the rail tanks (42 & 62 Gal under cab LHS) New SYNC powered New hands free connectivity with SYNC 18

19 2011 MY F650/ F750 Mid Year Actions Switches: Electrical: Bodybuilder switches optional in I/P (wiring architecture is in all vehicles) All new harnesses for Gateway Module (electrical connectors are carryover) Mirrors: New sail mounted exterior side view mirror in 96 & 102 wide 19

20 2012 MY F650/ F L 3V Gas Engine Engine: 6.8L 3V (362 HP/ 457 lbs-ft torque) late availability Also, available in an optional 6.8L 3V gaseous fuel prep package Trans.: New 6 speed 6R140 trans (with and without optional stationary PTO prep package) Mounting: Engine & Transmission mounting system Wheelbase: Offerings from 158 to 281 Cooling: Radiator module with Ford provided fan/ clutch and new shroud Controls: Single powertrain control module for engine & transmission DYNO: DYNO emissions cert emissions Fuel Tanks: Outside the rail tanks (42 & 62 Gal under cab LHS) Exhaust: Utilizing Ford supplied exhaust compatible with 6.8L engine Emissions: DYNO Cert Emissions Coolant: OAT Engine Coolant (Ford spec WSS-M97B44-D) Important: Do Not Mix Coolants 20

21 2011 MY F650/ F750 Mid Year Actions Vehicle: F650 low profile and dock height GVWRs up to 30K lbs / 33K GCWR; (Gas Engine Only) Exterior: Body side molding deleted on Regular Cabs Expanded usage of mud flaps on the F350 Chassis Cabs Exhaust: New Diesel Engine side outlet wheelbase dependent Enlarged Circle View Diesel Engine 21

22 2012 MY F-150 MAJOR PRODUCT FEATURES F150 XLT The 2012MY Ford F 150 offers the right truck for each customer, whatever their needs. Work trucks, affordable Sport pickups (STX), the heart of the lineup XLT, Off road FX4, Lariat and King Ranch luxury, and top of the line Platinum sophisticated luxury. More space and more power, along with best mileage and towing capability, provide what buyers are looking for in a pickup. NEW FEATURES AND BENEFITS SUMMARY Feature Benefit s Heavy Duty Payload Introduce Heavy Payload on Crew Cab 157 wheelbase (XL, XLT & Lariat) Light Duty Payload Introduce Light Duty Payload on Super Cab 163 wheelbase (XL & XLT) 17 Aluminum Wheel Expand usage of 17 Aluminum Wheel - XL Optional E-Locker Rear Axle Rear Breaks Towing Functionality A4WD MSOF Delete Replace 9.75 limited slip rear axles with E-Locker Thicker Rear Rotors (22 mm), caliper & linings Neutral Tow on all 4x4 Two Speed TOD on Lariat, King Ranch, Platinum, Harley Davison, and Mark LT Manual Shift On the Fly delete on XL, STR, & XLT 22

23 2012 MY F-150 New Features & Mid Year Actions 2011 MY Mid Year Actions 3.5L engine is available on F150 Reg. 4x2,Super Cab 4x4 & Super Crew 4x4 3.7L engine is available is standard on F150 4x4 Super Cab Skid Plates on 4x4 available as a fleet option XLT Reverse Sensing system on XLT Fleet Option 2012 MY Actions Introduce Heavy Payload on Crew Cab 157 wheelbase (XL, XLT & Lariat) Introduce Light Duty Payload on Super Cab 163 wheelbase (XL & XLT) Introduce Neutral Tow functionality standard on all 4X4 vehicles Replace 9.75 limited slip rear axles with E-Locker rear axle except for heavy payload 7-lug limited slip, which remains carryover ( limited slip axle remains in the program as optional on 3.7L engine) Delete Manual Shift on the Fly (MSOF) program 3.7L 4x4 will only be offered with Electronic Shift on the Fly (ESOF) 5.0L 4x4 will be offered only with ESOF or Two Speed TOD Expand current XLT 17 Aluminum wheel as option for XL (Usage Charge) Brakes New Thicker Rear Rotors (22 mm), caliper & linings 23

24 2012 MY Alternate Fuel - Buyers Guide 24

25 IMPORTANT PHONE NUMBERS AND WEB SITES INTENDED FOR GENERAL USERS & CUSTOMERS OF COMPLETED VEHICLES Ford Customer Assistance: Customer Assistance Center: Roadside Assistance Center: Web Site: Ford RV - Customer Assistance Center: To locate the nearest RV service center: INTENDED FOR FINAL STAGE MANUFACTURERS & VEHICLE MODIFIERS Ford Truck Body Builders Advisory Services (BBAS) including F53 Class A Motorhome Chassis and F59 Commercial Stripped Chassis Truck: Web Site: Information requests should be submitted through the web site (Contact Us.. (Drop Down Menu) E Mail Address: bbasqa@ford.com List of Ford Pool Accounts and Qualified Vehicle Modifiers: Other QVM Participants or Showroom Then: Select the desired vehicle type (Ambulance, Motorhome, etc.) Choose a chassis type (if required) Modifier Links Qualified Vehicle Modifiers Ford Alternative Fuels Information: Vehicle models available, list of authorized Ford dealers and Leaf & Road Newsletter FLEET Select #5 Ford Component Sales: Office and Fax: Vehicle Special Order, VSO Fleet Sales: FLEET Select #4 25

26 OBTAINING PUBLICATIONS Ford Truck Body Builders Layout Book: Access via The latest information appears on the web site. Incomplete Vehicle Manuals: Access at under Publications. Ford Recreation Vehicle and Trailer Towing Book The Book 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) , leave name and shipping address, or Fax to (248) This Book can also be accessed via the web at under Publications. Service Publications: The Ford Technical Publications Catalog lists the service publications available, and includes pricing, an order form, and a mailer. Contact Helm, Inc. at Some Service Publications are also available online at See Bulletin Q 118 on the BBAS website for additional information. 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. Access the bulletins via the web at under Bulletins. Ford Truck Quality Program Guidelines (QVM): This manual provides guidelines for final stage manufacturer modifying Ford products. It also includes an introduction to process controls, quality controls, customer support and management practices. Access the guidelines via the web at under Publications. Disclaimer: Information herein was correct when approved for printing. Ford Motor Company reserves the right to discontinue or change at any time specification designs or program without incurring obligation 26

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