brakes FORD E SERIES 2015 4.G User Guide

RECOMMENDED TOWING WEIGHTS
Note:Calculate the maximum trailer weight for all cutaway vehicles by
subtracting the weight of your vehicle (including incomplete vehicle
weight and payload, which includes second unit body weight, cargo and
passengers) from the gross combined weight. Otherwise, maximum
trailer weight is 10000 pounds (4536 kilograms).
Note:Do not exceed the trailer weight for your vehicle configuration
listed in the chart below.
Note:Make sure to take into consideration trailer frontal area. Do not
exceed 60 feet
2(5.57 meters2) trailer frontal area.
Note:Exceeding this limitation may significantly reduce the
performance of your towing vehicle. Selecting a trailer with a low
aerodynamic drag and rounded front design helps optimize performance
and fuel economy.
Note:For high altitude operation, reduce the gross combined weight by
2% per 1000 feet (300 meters) starting at the 1000 foot (300 meter)
elevation point.
Note:Certain states require electric trailer brakes for trailers over a
specified weight. Be sure to check state regulations for this specified
weight. The maximum trailer weights listed may be limited to this
specified weight, as your vehicle’s electrical system may not include the
wiring connector needed to use electric trailer brakes.
Your vehicle may tow a trailer provided the maximum trailer weight is
less than or equal to the maximum trailer weight listed for your vehicle
configuration on the following chart.
To calculate the maximum loaded trailer weight for your vehicle:
1. Start with the gross combined weight rating for your vehicle model
and axle ratio. See the following chart.
2. Subtract all of the following that apply to your vehicle:
•Vehicle curb weight
•Hitch hardware weight, such as a draw bar, ball, locks or weight
distributing
•Driver weight
•Passenger(s) weight
•Payload, cargo and luggage weight
•Aftermarket equipment weight.
3. This equals the maximum loaded trailer weight for this combination.
Note:The trailer tongue load figures into the payload for your vehicle.
Reduce the total payload by the final trailer tongue weight.
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Remember to account for the trailer tongue weight as part of your
vehicle load when calculating the total vehicle weight.
Trailer Towing Connector (Vehicles with a Trailer Towing Package
and 7–Pin Connector)
When attaching the trailer wiring
connector to your vehicle, only use
a proper fitting connector that
works with the vehicle and trailer
functions. If your vehicle has a
trailer towing package, it may have
a 7–pin connector. Some connectors
may have the SAE J2863 logo,
which confirms that it is the proper
wiring connector and works correctly with your vehicle.
Color Function
1. Yellow Left turn signal and stop lamp
2. White Ground (-)
3. Blue Electric brakes
4. Green Right turn signal and stop lamp
5. Orange Battery (+)
6. Brown Running lights
7. Grey Reverse lights
Hitches
Do not use a hitch that either clamps onto the bumper or attaches to the
axle.
Distribute the trailer load so 10-15% of the total trailer weight is on the
tongue.
Weight-Distributing Hitches
WARNING:Do not adjust a weight-distributing hitch to any
position where the rear bumper of the vehicle is higher than it
was before attaching the trailer. Doing so will defeat the function of the
weight-distributing hitch, which may cause unpredictable handling, and
could result in serious personal injury.
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When hooking-up a trailer using a weight-distributing hitch, always use
the following procedure:
1. Park the loaded vehicle, without the trailer, on a level surface.
2. Measure the height to the top of your vehicle’s front wheel opening
on the fender. This is H1.
3. Securely attach the loaded trailer to your vehicle without the
weight-distributing bars connected.
4. Measure the height to the top of your vehicle’s front wheel opening
on the fender a second time. This is H2.
5. Install and adjust the tension in the weight-distributing bars so that
the height of your vehicle’s front wheel opening on the fender is
approximately halfway between H1 and H2.
6. Check that the trailer is level or slightly nose down toward your
vehicle. If not, adjust the ball height accordingly and repeat
Steps 2–6.
Once the trailer is level or slightly nose down toward the vehicle:
•Lock the bar tension adjuster in place.
•Check that the trailer tongue securely attaches and locks onto the
hitch.
•Install safety chains, lighting, and trailer brake controls as required by
law or the trailer manufacturer.
Safety Chains
Note:Do not attach safety chains to the bumper.
Always connect the trailer’s safety chains to the frame or hook retainers
of your vehicle hitch.
To connect the trailer’s safety chains, cross the chains under the trailer
tongue and allow enough slack for turning tight corners. Do not allow the
chains to drag on the ground.
Trailer Brakes
WARNING: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.
Electric brakes and manual, automatic or surge-type trailer brakes are
safe if you install them properly and adjust them to the manufacturer’s
specifications. The trailer brakes must meet local and federal regulations.
The rating for the tow vehicle’s braking system operation is at
the gross vehicle weight rating, not the gross combined weight
rating.
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Separate functioning brake systems are required for safe control
of towed vehicles and trailers weighing more than 1500 pounds
(680 kilograms) when loaded.
Integrated Trailer Brake Controller (If Equipped)
WARNING:The Ford TBC has only been verified to be
compatible with trailers having electric-actuated drum brakes
(one to four axles) and some electric-over-hydraulic (EOH) brakes. It
will not activate hydraulic surge-style trailer brakes. It is the
responsibility of the customer to ensure that the trailer brakes are
adjusted appropriately, functioning normally and all electric connections
are properly made. Failure to do so may result in loss of vehicle
control, crash or serious injury.
When used properly, the trailer brake controller assists in smooth and
effective trailer braking by powering the trailer’s electric or
electric-over-hydraulic brakes with a proportional output based on the
towing vehicle’s brake pressure.
The controller user interface consists of the following:
A.+ and - (Gain adjustment buttons):Pressing these buttons adjusts
the controller’s power output to the trailer brakes in 0.5 increments. You
can increase the gain setting to 10.0 (maximum trailer braking) or
decrease it to 0 (no trailer braking). Pressing and holding a button raises
or lowers the setting continuously. The gain setting displays in the
message center as follows: TBC GAIN = XX.X.
B
A
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The controller shows gain setting, output bar graph, and trailer
connectivity status in the information display. They appear in the
information display as follows:
•TBC GAIN = XX.X NO TRAILER:Shows the current gain setting
during a given ignition cycle and when adjusting the gain. This also
displays if you use the manual control lever or make gain adjustments
with no trailer connected.
•TBC GAIN = XX.X OUTPUT=//////:Displays when you push
your vehicle’s brake pedal, or when you use the manual control. Bar
indicators illuminate in the information display to indicate the amount
of power going to the trailer brakes relative to the brake pedal or
manual control input. One bar indicates the least amount of output;
six bars indicate maximum output.
•TRAILER CONNECTED:Displays when the system senses a
correct trailer wiring connection (a trailer with electric trailer brakes)
during a given ignition cycle.
•TRAILER DISCONNECTED:Displays, accompanied by a single
audible chime, when the system senses a trailer connection and then
a disconnection, either intentional or unintentional, during a given
ignition cycle. It also displays if a truck or trailer-wiring fault occurs
causing the trailer to appear disconnected. This message can also
display if you use the manual control lever without a trailer
connected.
B.Manual control lever:Slide the control lever to the left to turn on
the trailer’s electric brakes independent of the tow vehicle’s brakes. See
the followingProcedure for adjusting gainsection for instructions on
proper use of this feature. If you use the manual control while the brake
is also applied, the greater of the two inputs determines the power sent
to the trailer brakes.
•Stop lamps:Using the manual control lever illuminates both the
trailer brake lamps and your vehicle brake lamps except the center
high-mount stop lamp, if you make the proper electrical connection
to the trailer. Pressing your vehicle brake pedal also illuminates both
trailer and vehicle brake lamps.
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Procedure for Adjusting Gain
Note:Only perform this procedure in a traffic-free environment at
speeds of approximately 20–25 mph (30–40 km/h).
The gain setting sets the trailer brake controller for the specific towing
condition. You should change the setting as towing conditions change.
Changes to towing conditions include trailer load, vehicle load, road
conditions and weather.
The gain should be set to provide the maximum trailer braking assistance
while making sure the trailer wheels do not lock when using the brakes.
Locked trailer wheels may lead to trailer instability.
1. Make sure the trailer brakes are in good working condition,
functioning normally and properly adjusted. See your trailer dealer if
necessary.
2. Hook up the trailer and make the electrical connections according to
the trailer manufacturer’s instructions.
3. When you plug in a trailer with electric or electric-over-hydraulic
brakes,TRAILER CONNECTEDappears in the information display.
4. Use the gain adjustment (+ and -) buttons to increase or decrease
the gain setting to the desired starting point. A gain setting of 6.0 is a
good starting point for heavier loads.
5. In a traffic-free environment, tow the trailer on a dry, level surface at
a speed of 20–25 mph (30–40 km/h) and squeeze the manual control
lever completely.
6. If the trailer wheels lock up, indicated by squealing tires, reduce the
gain setting. If the trailer wheels turn freely, increase the gain setting.
Repeat Steps 5 and 6 until the gain setting is at a point just below
trailer wheel lock-up. If towing a heavier trailer, trailer wheel lock-up
may not be attainable even with the maximum gain setting of 10.
Explanation of Information Display Warning Messages
Note:An authorized dealer can diagnose the trailer brake controller to
determine exactly which trailer fault has occurred. However, your Ford
warranty doesnotcover this diagnosis if the fault is with the trailer.
TRAILER BRAKE MODULE FAULT:Displays in response to faults
sensed by the trailer brake controller, accompanied by a single chime. If
this message appears, contact an authorized dealer as soon as possible
for diagnosis and repair. The controller may still function, but
performance may be degraded.
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WIRING FAULT ON TRAILER:Displays when there is a short circuit
on the electric brake output wire. If theWIRING FAULT ON TRAILER
message displays, accompanied by a single chime, with no trailer
connected, the problem is with your vehicle wiring between the trailer
brake controller and the 7–pin connector at the bumper. If the message
only displays with a trailer connected, the problem is with the trailer
wiring. Consult your trailer dealer for assistance. This can be a short to
ground (such as a chaffed wire), short to voltage (such as a pulled pin
on trailer emergency breakaway battery) or the trailer brakes may be
drawing too much current.
Points to Remember
Note:Do not attempt removal of the trailer brake controller without
consulting theWorkshop Manual.Damage to the unit may result.
•Adjust gain setting before using the trailer brake controller for the
first time.
•Adjust gain setting, using the procedure above, whenever road,
weather and trailer or vehicle loading conditions change from when
the gain was initially set.
•Only use the manual control lever for proper adjustment of the gain
during trailer setup. Misuse, such as application during trailer sway,
could cause instability of trailer or tow vehicle.
•Avoid towing in adverse weather conditions. The trailer brake
controller does not provide anti-lock control of the trailer wheels.
Trailer wheels can lock up on slippery surfaces, resulting in reduced
stability of trailer and tow vehicle.
•The trailer brake controller is equipped with a feature that reduces
output at vehicle speeds below 11 mph (18 km/h) so trailer and
vehicle braking is not jerky or harsh. This feature is only available
when applying the brakes using your vehicle’s brake pedal, not the
controller.
•The controller interacts with the brake control system and powertrain
control system of your vehicle to provide the best performance on
different road conditions.
•Your vehicle’s brake system and the trailer brake system work
independently of each other. Changing the gain setting on the
controller does not affect the operation of your vehicle’s brakes
whether you attach a trailer or not.
•When you turn the engine off, the controller output is disabled and
the display and module shut down. The controller module and display
turn on when you turn the ignition on.
•The trailer brake controller is only a factory-installed or
dealer-installed item. Ford is not responsible for warranty or
performance of the controller due to misuse or customer installation.
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Trailer Lamps
WARNING:Never connect any trailer lamp wiring to the
vehicle’s tail lamp wiring; this may damage the electrical system
resulting in a fire. Contact an authorized dealer as soon as possible for
assistance in proper trailer tow wiring installation. Additional electrical
equipment may be required.
Trailer lamps are required on most towed vehicles. Make sure all running
lights, brake lights, turn signals and hazard lights are working.
Before Towing a Trailer
Practice turning, stopping and backing up to get the feel of your
vehicle-trailer combination before starting on a trip. When turning, make
wider turns so the trailer wheels clear curbs and other obstacles.
When Towing a Trailer
•Do not drive faster than 70 mph (113 km/h) during the first 500 miles
(800 kilometers).
•Do not make full-throttle starts.
•Check your hitch, electrical connections and trailer wheel lug nuts
thoroughly after you have traveled 50 miles (80 kilometers).
•When stopped in congested or heavy traffic during hot weather, place
the gearshift in positionPto aid engine and transmission cooling and
to help air conditioning performance.
•Turn off the speed control with heavy loads or in hilly terrain. The
speed control may turn off automatically when you are towing on
long, steep grades.
•Shift to a lower gear when driving down a long or steep hill. Do not
apply the brakes continuously, as they may overheat and become less
effective.
•If your transmission is equipped with a Grade Assist or Tow/Haul
feature, use this feature when towing. This provides engine braking
and helps eliminate excessive transmission shifting for optimum fuel
economy and transmission cooling.
•If your vehicle is equipped with AdvanceTrac™ with RSC, this system
may turn on during typical cornering maneuvers with a heavily loaded
trailer. This is normal. Turning the corner at a slower speed while
towing may reduce this tendency.
•If you are towing a trailer frequently in hot weather, hilly conditions,
at the gross combined weight rating (or any combination of these
factors), consider refilling your rear axle with synthetic gear lubricant
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Before driving through standing water, check the depth. Never drive
through water that is higher than the bottom
of the wheel hubs.
When driving through standing water, drive
very slowly and do not stop your vehicle. Your
brake performance and traction may be
limited. After driving through water and as
soon as it is safe to do so:
•Lightly press the brake pedal to dry the
brakes and to check that they work.
•Check that the horn works.
•Check that the exterior lights work.
•Turn the steering wheel to check that the steering power assist works.
FLOOR MATS
WARNING:Always use floor mats that are designed to fit the
foot well of your vehicle. Only use floor mats that leave the pedal
area unobstructed. Only use floor mats that are firmly secured to
retention posts so that they cannot slip out of position and interfere
with the pedals or impair safe operation of your vehicle in other ways.
WARNING:Pedals that cannot move freely can cause loss of
vehicle control and increase the risk of serious personal injury.
WARNING:Always make sure that the floor mats are properly
attached to the retention posts in the carpet that are supplied
with your vehicle. Floor mats must be properly secured to both
retention posts to make sure mats do not shift out of position.
WARNING:Never place floor mats or any other covering in the
vehicle foot well that cannot be properly secured to prevent them
from moving and interfering with the pedals or the ability to control the
vehicle.
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Brakes
•Make sure brakes and parking brake are fully released.
Tires
•Maintain recommended air pressure.
Miscellaneous
•Make sure all linkages, cables, levers and pins under vehicle are
covered with grease to prevent rust.
•Move vehicles at least 25 feet (8 meters) every 15 days to lubricate
working parts and prevent corrosion.
Removing Vehicle from Storage
When your vehicle is ready to come out of storage, do the following:
•Wash your vehicle to remove any dirt or grease film build-up on
window surfaces.
•Check windshield wipers for any deterioration.
•Check under the hood for any foreign material that may have collected
during storage (mice/squirrel nests).
•Check the exhaust for any foreign material that may have collected
during storage.
•Check tire pressures and set tire inflation per the Tire Label.
•Check brake pedal operation. Drive the vehicle 15 feet (4.5 meters)
back and forth to remove rust build-up.
•Check fluid levels (including coolant, oil and gas) to make sure there
are no leaks and fluids are at recommended levels.
•If the battery was removed, clean the battery cable ends and inspect.
Contact your authorized dealer if you have any concerns or issues.
210Vehicle Care
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