brake FORD E SERIES 2002 4.G Owner's Manual

GCWR (Gross Combined Weight Rating)/Trailer Weights
EngineRear
axle
ratioMaximum
GCWR - kg
(lbs.)Trailer weight
range - kg
(lbs.)
(0-Maximum)Maximum
frontal area of
trailer - m
2
(ft2)
E-450 Stripped Chassis (dual rear wheel)
5.4L 4.105 897
(13 000)1 361 (3 000) 5.52 (60)
6.8L 4.639 072
(20 000)* 5.52 (60)
* Maximum trailer weight for all cutaway (E-350 and E-450) vehicles
must be calculated by subtracting the weight of the vehicle (including
incomplete vehicle weight, and payload which includes second unit
body weight, cargo, and passengers) from the GCW. Otherwise,
maximum trailer weight is 4 536 kg (10 000 lbs).
For high altitude operation reduce GCWR by 2% per 300 meters
(1 000 ft) elevation.
To determine the maximum trailer weight designed for your particular
vehicle as equipped, follow the sectionCalculating the load your
vehicle can tow/carryearlier in this chapter.
Your vehicle's load capacity is designated by weight, not by volume, so
you cannot necessarily use all available space when loading a vehicle.
Distribute the load so that only 10 to 15% of the total is on the tongue.
Tie down the load so that it does not shift and change the weight on the
hitch.
Towing a trailer places an additional load on your vehicle's engine,
transmission, axle, brakes, tires and suspension. Inspect these
components carefully after any towing operation.
Do not exceed the GVWR or the GAWR specified on the
certification label.
Towing trailers beyond the maximum recommended gross trailer
weight could result in engine damage, transmission/axle damage,
structural damage, loss of control, and personal injury.
Driving
168

Preparing to tow
Use the proper equipment for towing a trailer, and make sure it is
properly attached to your vehicle. See your dealer or a reliable trailer
dealer if you require assistance.
Hitches
Do not use or install hitches that clamp onto the bumper or to the axle.
Underbody hitches are acceptable if installed properly.
Safety chains
Always connect the trailer's safety chains to the frame or hook retainers
of the vehicle hitch. To connect the trailer's safety chains, cross the
chains under the trailer tongue and allow slack for turning corners.
If you use a rental trailer, follow the instructions that the rental agency
gives to you.
Do not attach safety chains to the bumper.
Trailer brakes
Electric brakes and manual, automatic or surge-type trailer brakes are
safe if installed properly and adjusted to the manufacturer's
specifications. The trailer brakes must meet local and Federal
regulations.
Do not connect a trailer's hydraulic brake system directly to your
vehicle's brake system. Your vehicle may not have enough
braking power and your chances of having a collision greatly increase.
The braking system of the tow vehicle is rated for operation at the
GVWR not GCWR.
Trailer lamps
Trailer lamps are required on most towed vehicles. Make sure your
trailer lamps conform to local and Federal regulations. See your dealer or
trailer rental agency for proper instructions and equipment for hooking
up trailer lamps.
Driving
169

Using a step bumper (if equipped)
The rear bumper is equipped with an integral hitch and only requires a
ball with a 25.4 mm (one inch) shank diameter. The bumper has a
2 270 kg (5 000 lb.) trailer weight and 227 kg (500 lb.) tongue weight
capacity.
If it is necessary to relocate the trailer hitch ball position, a
frame-mounted trailer hitch must be installed.
Driving while you tow
When towing a trailer:
²Ensure that you turn off your speed control. The speed control may
shut off automatically when you are towing on long, steep grades.
²Consult your local motor vehicle speed regulations for towing a trailer.
²Use D (Drive) or a lower gear when towing up or down steep hills.
This will eliminate excessive downshifting and upshifting for optimum
fuel economy and transmission cooling.
²Anticipate stops and brake gradually.
When descending long, steep downhill grades, always use a lower gear to
provide engine braking to save wear on brakes. Use Drive (Overdrive
OFF) on moderately steep hills, Second (2) on steep hills, and First (1)
on very steep hills.
Servicing after towing
If you tow a trailer for long distances, your vehicle will require more
frequent service intervals. Refer to your scheduled maintenance guide for
more information.
Trailer towing tips
²Practice turning, stopping and backing up before starting on a trip to
get the feel of the vehicle trailer combination. When turning, make
wider turns so the trailer wheels will clear curbs and other obstacles.
²Allow more distance for stopping with a trailer attached.
²The trailer tongue weight should be 10±15% of the loaded trailer
weight.
Driving
170

For commercial stripped chassis
vehicles, the fuel pump shut-off
switch is located on a bracket above
the brake pedal.
Use the following procedure to reset the fuel pump shut-off switch.
1. Turn the ignition to the OFF position.
2. Check the fuel system for leaks.
3. If no fuel leak is apparent, reset the fuel pump shut-off switch by
pushing in on the reset button.
4. Turn the ignition to the ON position. Pause for a few seconds and
return the key to the OFF position.
5. Make a further check for leaks in the fuel system.
Roadside emergencies
176

Passenger compartment fuse panel
The fuse panel is located below and to the left of the steering wheel by
the brake pedal. Remove the panel cover to access the fuses.
To remove a fuse use the fuse puller tool provided on the fuse panel
cover.
The fuses are coded as follows.
Fuse/ Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
1 20A 4WABS Module
2 15A Brake Warning Lamp, Instrument
Cluster, Warning Chime, 4WABS
Relay, Warning Indicators, Low
Vacuum Warning Switch (Diesel
Only)
1234
5
7
689101142
43
44 13 12 14
15 16 17
19 18
2021 22 23
25 24
26 27 28 29
31 30 32 33 3435
37
3638 3940
41
Roadside emergencies
178

Fuse/ Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
3 15A Main Light Switch, RKE Module,
Radio, Instrument Illumination, E
Traveler VCP and video screens,
Overhead Console
4 15A Power Locks w/RKE, Illuminated
Entry, Warning Chime, Modified
Vehicle, Main Light Switch,
Courtesy Lamps
5 20A RKE Module, Power Lock
Switches, Memory Lock, Power
Locks with RKE
6 10A Brake Shift Interlock, Speed
Control, DRL Module
7 10A Multi-Function Switch, Turn
Signals
8 30A Radio Capacitor(s), Ignition Coil,
PCM Diode, PCM Power Relay,
Fuel Heater (Diesel Only), Glow
Plug Relay (Diesel Only)
9 30A Wiper Control Module, Windshield
Wiper Motor
10 20A Main Light Switch, Park Lamps,
License Lamp,(External Lamps)
Multi-Function Switch
(Flash-to-pass)
11 15A Brake Pressure Switch,
Multi-Function Switch (Hazards),
Brake Lamp Switch, Brake Lamps
12 15A Transmission Range (TR) Sensor,
Backup Lamps, Auxiliary Battery
Relay
13 15A Blend Door Actuator, A/C Heater,
Function Selector Switch
Roadside emergencies
179

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
12 60A** Engine Compartment Fuses 25,
27
13 50A** Blower Motor Relay (Blower
Motor)
14 30A** Trailer Running Lamps Relay,
Trailer Backup Lamps Relay
15 40A** Main Light Switch, Daytime
Running Lights (DRL)
16 50A** Auxiliary Blower Motor Relay
17 30A** Fuel Pump Relay
18 60A** I/P Fuses 40, 41,26, 33, 39
19 60A** 4WABS Module
20 20A** Electric Brake Controller
21 50A** Modified Vehicle Power
22 40A** Trailer Battery Charge Relay,
Modified Vehicles
23 60A** Ignition Switch, Fuse Panel
24 20A* Natural Gas Tank Valves (NGV
only)
25 20A* NGV Module (Natural Gas Only)
26 10A* A/C Clutch (4.2L Only)
27 15A* DRL Module, Horn Relay
28 Ð PCM Diode
29 Ð Not Used
A Ð Not Used
B Ð Stop Lamp Relay
C Ð Trailer Backup Lamps Relay
D Ð Trailer Running Lamps Relay
E Ð Trailer Battery Charge Relay
F Ð IDM Relay (Diesel Only), A/C
Clutch Relay (4.2L Only)
G Ð PCM Relay
Roadside emergencies
183

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
H Ð Blower Motor Relay
J Ð Horn Relay
K Ð Fuel Pump Relay
* Mini Fuses ** Maxi Fuses
Relays
Relays are located in the power distribution box and should be replaced
by qualified technicians.
CHANGING THE TIRES
If you get a flat tire while driving, do not apply the brake heavily.
Instead, gradually decrease your speed. Hold the steering wheel firmly
and slowly move to a safe place on the side of the road.
Spare tire information
The spare tire for your vehicle is stowed under the rear of your vehicle
(except cutaway and stripped chassis models).
To remove the spare tire:
1. Open both rear doors and remove
thumb screw and anti-theft bracket.
If finger pressure will not remove
the thumb screw, use the lug
wrench to loosen the screw.
2. Remove the access cover from
the rubber strip behind the left
door.
Roadside emergencies
184

Tire change procedure
Preparing to change the tire
To prevent the vehicle from moving when you change a tire, be
sure the parking brake is set, then block (in both directions) the
wheel that is diagonally opposite (other side and end of the vehicle) to
the tire being changed.
1. Park on a level surface.
2. Activate the warning flashers.
3. Place the gearshift in P (Park)(automatic transmission).
4. Apply the parking brake and turn
engine OFF.
5. Block the wheel that is diagonally
opposite the tire you are changing.
On E-450 vehicles, the parking
brake is on the transmission.
Therefore, the vehicle will not be
prevented from moving when a rear
wheel is lifted, even if the parking
brake is applied. Be sure to block both directions of the wheel that is
diagonally opposite to the wheel that is being lifted.
If the vehicle slips off the jack, you or someone else could be
seriously injured.
Roadside emergencies
186

JUMP STARTING YOUR VEHICLE
The gases around the battery can explode if exposed to flames,
sparks, or lit cigarettes. An explosion could result in injury or
vehicle damage.
Batteries contain sulfuric acid which can burn skin, eyes, and
clothing, if contacted.
Do not attempt to push-start your vehicle. Automatic
transmissions do not have push-start capability; also, the
catalytic conveter may become damaged.
Preparing your vehicle
When the battery is disconnected or a new battery is installed, the
transmission must relearn its adaptive strategy. As a result of this, the
transmission may shift firmly. This operation is considered normal and
will not affect function or durability of the transmission. Over time, the
adaptive learning process will fully update transmission operation to its
optimum shift feel.
1.Use only a 12±volt supply to start your vehicle.
2. Do not disconnect the battery of the disabled vehicle as this could
damage the vehicle's electrical system.
3. Park the booster vehicle close to the hood of the disabled vehicle
making sure the two vehiclesdo nottouch. Set the parking brake on
both vehicles and stay clear of the engine cooling fan and other moving
parts.
4. Check all battery terminals and remove any excessive corrosion before
you attach the battery cables. Ensure that vent caps are tight and level.
5. Turn the heater fan on in both vehicles to protect any electrical
surges. Turn all other accessories off.
Roadside emergencies
191