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T ABLE OF CONTENTS 1 General Information 2 Electrical 3 Installation Considerations 4 Cargo Mounting Considerations 5 Reference Information INTRODUCTION SECTIONS N OTE: The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue m[...]

SECTION 0 Introduction Contents Introduction ....................................................................................... 0-1 2010 Expedition SSV Modifiers Guide, 07/2009[...]

Introduction 0-1 Introduction Ford Motor Company has assembled this Expedition Special Service Vehicle (SSV) Modifiers Guide to assist vehicle modifiers in producing safe and quality products. Ford believes that safety and quality come first. This book is divided into topics pertinent to modifiers of vehicles. Reference is made to the current Ford [...]

SECTION 1 General Information Contents Section 1: General Information ........................................................ 1-1 Important Safety Notice ................................................................ 1-1 Warnings, Notices and Notes ................................................... 1-1 Making Safety Devices and Elements Inopera[...]

General Information 1-1 Section 1: General Information Important Safety Notice Note: The descriptions and specifications contained in this guide were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incu[...]

1-2 General Information Section 1: General Information The following list contains some general warnings that you should follow when you work on a vehicle. WARNING: • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires you to be under the vehicle. • Make sure that the ignition switch is always in t[...]

General Information 1-3 Section 1: General Information Special Service Vehicle (SSV) Definition Special Service Vehicles (SSV) are offered to fill the special needs of police agencies that a standard patrol car can not. SSV Standard Package Deletes Item Floor console Floor mats Fog lamps Third-row seat Standard Equipment System Description Powertra[...]

1-4 General Information Section 1: General Information Standard Equipment System Description Interior Second and third row coat hooks Second row map lights Manual A/C with auxiliary climate controls AM/FM single CD, 6-premium speakers (160-watts peak), driver adjusted speed compensated volume, partitioned audio, rear seat controls and MP3 capabilit[...]

General Information 1-5 Section 1: General Information Miscellaneous Options (See sales brochure for complete list of available options) Item Description Exterior Options Daytime running lamps (43D) Engine block heater (41H) Heated sideview mirrors (54H) Running boards (4x4 only) (186) Seat Options First row 40/60 split bench cloth with power adjus[...]

1-6 General Information Section 1: General Information Vehicle Certification (VC) Label Code Positions Position Description 1 Exterior paint code 2 Region code 3 District Special Order (DSO) 4 Wheelbase code 5 Interior trim code 6 Tape/paint pinstripe code 7 Radio code 8 Axle code 9 Transmission code 10 Spring code 11 Powertrain calibration informa[...]

General Information 1-7 Section 1: General Information 1. Exterior Paint Color Code The first set of numbers/letters listed indicate the vehicle primary body color code. The second set of letters/numbers listed (if applicable) indicate a 2-tone or accent body color code. • DX — Dark Blue Pearl • UG — White Platinum • UH — Tuxedo Black M[...]

1-8 General Information Section 1: General Information 7. Radio Type • 1 — AM/FM stereo with in-dash, 6-disc CD changer and clock • F — AM/FM stereo CD player, navigation system and clock • S — Premium electric AM/FM stereo CD player • T — Premium AM/FM stereo with in-dash CD changer and clock • U — Premium AM/FM stereo with in-[...]

General Information 1-9 Section 1: General Information 11. Powertrain Calibration Information Powertrain calibration information is printed in the lower right corner of the VC label. Only the base calibration information is printed. Revision levels will not appear. Powertrain calibration information is limited to a maximum of 5 characters per line [...]

1-10 General Information Section 1: General Information New Vehicle Storage — Body • Wash vehicle thoroughly to remove dirt, grease, oil, tar or mud from exterior surfaces and underside of front fender. • Periodically wash vehicles stored in exposed locations. • Touch up exposed raw or primed metal to provide rust protection. • Cover chro[...]

General Information 1-11 Section 1: General Information Tire Pressure Monitoring System (TPMS) Principles of Operation The tire pressure monitoring system (TPMS) monitors the air pressure of all 4 regular road tires. The tire pressure sensors, attached to each rim by a metal band located in the drop well, transmit via a 315 Mhz radio frequency sign[...]

1-12 General Information Section 1: General Information The TPMS, as delivered from the Ford Motor Company, complies with part 15 of the FCC rules and with RS-210 of Industry Canada. Operation is subject to the following 2 conditions: • This device may not cause harmful interference • This device must accept any interference received, including[...]

General Information 1-13 Section 1: General Information As the ambient temperature decreases by 6 ° C (10 ° F), tire pressure decreases 7 kPa (1 psi). Adjust the tire pressure by 7 kPa (1 psi) for each 6 ° C (10 ° F) ambient temperature drop as necessary to keep the tire at the specified vehicle certification (VC) label pressure. Refer to the f[...]

SECTION 2 Electrical Contents Section 2: Electrical ......................................................................... 2-1 Electrical Basics ........................................................................... 2-1 Electrical Systems Management .................................................. 2-2 Generator Output ....................[...]

Electrical 2-1 Section 2: Electrical Electrical Basics Inside a vehicle, electricity is supplied through powered wires (commonly called ‘‘hot’’ wires), comparable to the pressurized supply pipes of a plumbing system. At various points along the wires are outlets in the form of lights, switches and receptacles. Turning on a light switch is s[...]

2-2 Electrical Section 2: Electrical Electrical Systems Management Care must be given in deciding what equipment should be installed into a police vehicle given the power demands of the equipment and the power available from the vehicle. A power load strategy should be developed to minimize the risk of running out of power. Examine the proposed equ[...]

Electrical 2-3 Section 2: Electrical Component Amps Base Miscellaneous Base Loads 16.5 Cooling Cooling Fan (electric fan clutch) 2.2 Climate Control A/C Clutch 3.5 A/C Fan-to-Face — High Speed 18.9 A/C Fan-to-Face — M/H Speed 13.4 Heater Fan-to-Foot — M/H Speed 12.5 Auxiliary Blower — M/H Speed 8.5 Auxiliary Blower — High Speed 9.5 Lighti[...]

2-4 Electrical Section 2: Electrical PCM — Red Area NOTICE: DO NOT make electrical connections to vehicle electrical systems not specifically designed for police equipment installations. Damage to the electrical system can occur. Do not install any components into the PCM or PCM harness. Connecting into this system may affect engine and transmiss[...]

Electrical 2-5 Section 2: Electrical • Disconnect the negative battery cable of vehicles stored on site to reduce the possibility of draining the battery by lights or other equipment. • Do not allow control panels attached to the instrument panel to protrude into the driver and passenger air bag deployment zones. For additional information, ref[...]

2-6 Electrical Section 2: Electrical Equipment Grounding Guidelines • Do not ground the body to the transmission or transmission crossmember. Ground accessories to the chassis or the vehicle battery. • Splicing into circuitry relating to the electronic engine and/or transmission control systems is not acceptable because of the adverse effect on[...]

Electrical 2-7 Section 2: Electrical • Determine the terminal type. Base your decision on wire gauge, current carrying capacity, connector type and insulation type. — Use non-detent low insertion force terminals whenever possible. — Do not use low insertion force female terminals in weather-resistant connectors. — Analyze circuit requiremen[...]

2-8 Electrical Section 2: Electrical • Use 135% of the fuse rating when sizing wiring to protect the circuit in the event of an overload. Fuses will last for 1 hour at 135% of their rating. — Total current draw is the sum of the base vehicle’s circuit current requirement (measured with an ammeter) and the anticipated add-on component current [...]

Electrical 2-9 Section 2: Electrical • Use greased or sealed connectors in floor pan troughs which are subject to moisture coming through the carpeting. • Use XLPE insulation for uncovered runs that exceed 305 mm (12 in). Electrical Protection • Correctly route wires away from noise-generating wires or components. However, if routing near noi[...]

2-10 Electrical Section 2: Electrical • Scroll — Similar to convolute, but without the ridges. Scroll is used where harness rigidity is required, especially for maintaining critical locator dimensions. Use scroll for short lengths only, as it is quite inflexible. Note: This is not meant to be an all-inclusive list of methods for physically prot[...]

Electrical 2-11 Section 2: Electrical • Route wires to avoid metal edges, screws, trim fasteners and abrasive surfaces. When such routing is not possible, use protective devices (shields, caps) to protect the wires. Cover metal edges with a protective shield and fasten the wiring within 76 mm (3 in) on each side of the edge (see figure below). ?[...]

2-12 Electrical Section 2: Electrical Wire Retention and Routing Use the following criteria to determine the location of retainers: • Size and weight of wire bundle. • Holes with poor accessibility that prevent installation of locators. • Movement of wires that can result in abrasion, squeaks and rattles. • When wiring is routed between 2 m[...]

Electrical 2-13 Section 2: Electrical For retainer screws, the following guidelines apply: • Avoid using fasteners that are too long for the application or are in an area which might damage vehicle components, including wiring, brake lines, fuel tank and lines, powertrain components, exhaust system and suspension. • Do not use pointed screws fo[...]

2-14 Electrical Section 2: Electrical Splices and Repairs For quality splicing and to reduce potential problems, the following guidelines are recommended: • Stagger the splices within a harness to reduce increased harness diameter. Splice only on straight areas as installed, not on bends. • Strip wire ends making sure that individual conductor [...]

Electrical 2-15 Section 2: Electrical 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist the wires together. 5. Note: Use resin-core mildly-activated (RMA) solder. Do not use acid-core solder. Solder wires together. 6. Note: Wait for solder to cool before moving wires. Bend wire 1 back in a straight line. 2010 Expedition [...]

2-16 Electrical Section 2: Electrical 7. Note: Overlap tubing on both wires. Evenly position heat shrink tubing over wire repair. 8. Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 2010 Expedition SSV Modifiers Guide, 07/2009[...]

Electrical 2-17 Section 2: Electrical 9. Reconnect the battery ground cable. Sealed Connectors Ford Part Number Part Name Class E6FZ-14488-A Butt Connector C Gauge: 18-22, Color: Red E6FZ-14488-B Butt Connector C Gauge: 14-16, Color: Blue E6FZ-14488-C Butt Connector C Gauge: 10-12, Color: Yellow Heat Shrinkable Tubing (Heat Shrink) (Ford Specificat[...]

2-18 Electrical Section 2: Electrical 4. Select the appropriate wire slice for the wires to be spliced from Rotunda Wire Splice Kit 164-R5903. 5. Note: Rotunda 164-R5901 Pro-Crimper supplied with the wire splice kit is the only tool that can be used with these splices. Identify the appropriate chamber on the Rotunda Pro-Crimper by matching the wire[...]

Electrical 2-19 Section 2: Electrical 8. Check for acceptable crimp. (1) Crimp should be centered on each end of the butt splice. (2) Wire insulation does not enter butt splice. (3) Wire is visible through inspection hole of splices. 9. Evenly position supplied heat shrink tubing over wire repair. 10. Use shielded heat gun to heat the repaired area[...]

2-20 Electrical Section 2: Electrical Rear Power Window Disable The rear power windows of the Expedition SSV can be disabled by disconnecting the rear window motor connectors (C701 [LH] and C801 [RH]). These connectors are located inside the door, behind the door trim panel. While they are disabled, the master window control switch will not control[...]

SECTION 3 Installation Considerations Contents Section 3: Installation Considerations.............................................. 3-1 Mobile Radio Installation Guidelines ............................................ 3-1 General Information .................................................................. 3-1 Spotlight Installation Location .....[...]

Installation Considerations 3-1 Section 3: Installation Considerations Mobile Radio Installation Guidelines NOTICE: This information has been prepared for use by persons installing 2-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, [...]

3-2 Installation Considerations Section 3: Installation Considerations Radio transmitters are regulated by the Federal Communications Commission (FCC) in the United States. Compliance with FCC regulations is the responsibility of the manufacturer and/or user of transmitter equipment and not Ford Motor Company. Installation Guidelines WARNING: Do no[...]

Installation Considerations 3-3 Section 3: Installation Considerations Glass-mounted antennas should be kept as high as possible in the center of the rear window or windshield. Some vehicles use glass that contains a thin metallic coating for defrosting or to control solar gain; glass mount antennas may NOT function correctly when mounted on this t[...]

3-4 Installation Considerations Section 3: Installation Considerations If any vehicle radio interaction problems exist after following these guidelines, contact the radio equipment manufacturer for additional assistance. Additional Sources of Information Radio Frequency Interference: How to Find It and Fix It ISBN: 0-87259-375-4, The American Radio[...]

Installation Considerations 3-5 Section 3: Installation Considerations Item Description 1 Side curtain tether anchor bolt hole 2 A-pillar assist handle bracket lower mounting bolt hole 3 Center line 4 Spotlight shaft hole 5 Spotlight mount lower bolt hole 1. Mark a center line between the center of the side curtain tether anchor bolt hole and the A[...]

3-6 Installation Considerations Section 3: Installation Considerations Siren and Grille Lights The engine cooling system relies on correct airflow through the radiator to keep the engine at its correct operating temperature. When adding sirens and grille lights to a vehicle, make sure this airflow is not obstructed. Reduced airflow could put additi[...]

Installation Considerations 3-7 Section 3: Installation Considerations Safety Belt Retractor and Side Impact Sensor Item Description 1 Side impact sensor 2 Front safety belt retractor The front safety belt retractors are located in the base of the B-pillars. The pretensioner located in the buckle is referred to as the ‘‘safety belt buckle prete[...]

3-8 Installation Considerations Section 3: Installation Considerations WARNING: The front side impact sensors are located in the front doors. These are pressure sensors that measure the pressure change in the front door during an impact. Do not mount anything on or in the door. Do not cut any holes in the door sheet metal, trim or water seals. Fail[...]

Installation Considerations 3-9 Section 3: Installation Considerations Driver/passenger air bags affect the way police equipment can be mounted in police vehicles. Any surfaces that could come into contact with an air bag during deployment must not damage the air bag or alter its deployment path. Sharp edges, corners or protrusions could damage the[...]

3-10 Installation Considerations Section 3: Installation Considerations A reset event will set the interior lamps interrupt timer to 0. The reset events for the interior lamps interrupt timer are: turning on the interior lamps by using the dome lamp switch or opening any door (as detected by the door ajar switches). A reset event will set the deman[...]

SECTION 4 Cargo Mounting Considerations Contents Section 4: Cargo Mounting Considerations ..................................... 4-1 Cargo Area Equipment Mounting Guide ...................................... 4-1 Safety Belt Retractor and Side Impact Sensor (if equipped).................................................................................[...]

Cargo Mounting Considerations 4-1 Section 4: Cargo Mounting Considerations Cargo Area Equipment Mounting Guide NOTICE: When installing equipment, it is important to consider the available clearance between the brake lines and the fastener or component. Any fasteners or static components should allow a minimum of 15 mm (0.60 in) clearance to the bra[...]

4-2 Cargo Mounting Considerations Section 4: Cargo Mounting Considerations Item Description 1 Side impact sensor 2 Second row safety belt retractor 3 Third row safety belt retractor The second row safety belt retractors are located in the middle of the C-pillars. The third row safety belt retractors are located in the middle of the D-pillars. • D[...]

Cargo Mounting Considerations 4-3 Section 4: Cargo Mounting Considerations WARNING: The rear side impact sensors are located in the C-pillars. The installation of hardware must not interfere with the correct operation of the rear side impact sensors. Failure to follow these instructions may result in personal injury. Auxiliary Climate Control Syste[...]

4-4 Cargo Mounting Considerations Section 4: Cargo Mounting Considerations Cargo Loading WARNING: Ford recommends that police equipment be both secured and laterally aligned. Hard, stiff or sharp objects, especially when not secured or correctly located, pose a risk to the occupants. Aftermarket organizers that do not adequately deform in rear-impa[...]

Cargo Mounting Considerations 4-5 Section 4: Cargo Mounting Considerations • Low Risk Items — These items are soft in feel and pose a low risk of potential injury capability in collisions. Examples are: a soft camera case, biohazard kit in plastic boxes, gloves, safety rope, tow strap, traffic cones and sleeves, rain gear, riot gear (soft), eme[...]

SECTION 5 Reference Information Contents Section 5: Reference Information .................................................... 5-1 Engineering Drawings .................................................................. 5-1 Air Bag Deployment Interference ............................................. 5-1 Fuel Lines — Short Wheelbase...............[...]

Reference Information 5-1 Section 5: Reference Information Engineering Drawings Air Bag Deployment Interference WARNING: Do not place objects or mount equipment in front of the air bag module cover or in front seat areas that may come in contact with a deploying air bag, dash, tunnel or console-mounted equipment should be placed within the specifie[...]

5-2 Reference Information Section 5: Reference Information Figure 1. (1) 250 mm (9.8 in) from center of air bag door (2) 325 mm (12.8 in) from center of air bag door (3) 650 mm (25.6 in) Figure 2. 2010 Expedition SSV Modifiers Guide, 07/2009[...]

Reference Information 5-3 Section 5: Reference Information (1) 500 mm (19.7 in) (2) 300 mm (11.8 in) (3) 200 mm (8 in) Figure 3. No objects should be placed between the air bags due to air bag variability. (1) 300 mm (11.8 in) (2) 500 mm (19.7 in) (3) 260 mm (10.25 in) (4) 175 mm (7 in) WARNING: The front side impact sensors are located in the fron[...]

5-4 Reference Information Section 5: Reference Information Figure 4. The curtain airbag extends from the A-pillar to the D-pillar and from the roof rail to the beltline. • Do not mount equipment to the B-, C- and D-pillars above the beltline. • Do not mount equipment to the A-pillar above the beltline except for spotlights. Refer to Section 3: [...]

Reference Information 5-5 Section 5: Reference Information Fuel Lines — Short Wheelbase Item Description 1 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009[...]

5-6 Reference Information Section 5: Reference Information Fuel Lines — Long Wheelbase Item Description 1 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009[...]

Reference Information 5-7 Section 5: Reference Information Fuel Tank — Cut View, Short Wheelbase Item Description 1 Evaporative emissions hose 2 Fuel tank 3 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009[...]

5-8 Reference Information Section 5: Reference Information Fuel Tank — Cut View, Long Wheelbase Item Description 1 Evaporative emissions hose 2 Fuel tank 3 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009[...]

Reference Information 5-9 Section 5: Reference Information Fuel Tank — Bottom View, Short Wheelbase Item Description 1 Fuel lines 2 Fuel tank 2010 Expedition SSV Modifiers Guide, 07/2009[...]

5-10 Reference Information Section 5: Reference Information Fuel Tank — Bottom View, Long Wheelbase 2010 Expedition SSV Modifiers Guide, 07/2009[...]

Reference Information 5-11 Section 5: Reference Information Item Description 1 Fuel lines 2 Fuel tank Fuel Tank — Top View, Short Wheelbase 2010 Expedition SSV Modifiers Guide, 07/2009[...]

5-12 Reference Information Section 5: Reference Information Fuel Tank — Top View, Long Wheelbase 2010 Expedition SSV Modifiers Guide, 07/2009[...]

Reference Information 5-13 Section 5: Reference Information Fuel Pump Shut-Off Switch Brake Lines NOTICE: When installing equipment, it is important to consider the available clearance between the brake lines and the fastener or component. Any fasteners or static components should allow a minimum of 15 mm (0.60 in) clearance to the brake lines. Any[...]

5-14 Reference Information Section 5: Reference Information Item Description 1 Master cylinder 2 Brake booster 3 Brake lines 4 Brake control module Technical Specifications Item Specification Specification Make: Ford Model: Expedition Special Service Sales Code: — Vehicle (SSV) Engine Displacement Cubic Inches: 330 Liters: 5.4 Fuel System Sequent[...]

Reference Information 5-15 Section 5: Reference Information Item Specification Specification Torque 365 lb-ft @ 3,750 rpm Battery 750 cca Compression Ratio 9.8:1 Transmission Model: 6R80 Type: 6-speed electronic automatic with lockup torque converter and overdrive. Axle Ratio 3.73:1 Gross vehicle weight rating (GVWR) 3,333 kg (7,350 lb) (Expedition[...]

5-16 Reference Information Section 5: Reference Information Item Specification Specification Behind Third Row Seat (optional) 0.51 cu m (18 cu ft) (Expedition) or 1.21 cu m (42.6 cu ft) (Expedition EL) EPA Mileage Est. (mpg) City: 16/Highway: 22 Combined: 18 Mileage Est. (km/L) City: 6.8/Highway: 9.3 Combined: 7.7 2010 Expedition SSV Modifiers Guid[...]