248
ELECTRICAL WIRING
GENERAL PRACTICES
ADDITION OF LIGHTS OR ELECTRICAL DEVICES
Body Builders Layout Book
3
ELECTRICAL WIRING
2013
MODEL YEAR
www.fleet.ford.com/truckbbas
(Cont'd next page)
Additional Electrical information
can be accessed via the web at:
www.fleet.ford.com/truckbbas
under the “Bulletins” tab.
This section provides instructions for the addition
of electrical devices to the vehicle electrical system
by body builders.
Vehicles stored on site should have the negative
battery cable disconnected to minimize a “Dead
Battery” situation. This applies to both
“incomplete” and “complete” vehicles in storage.
After all electrical or vehicle modifications, perform on-
board diagnostics to the Body Control Module (BCM).
Road test vehicle and re-run the on-board diagnostics
to verify that no DTCs are present. If DTCs are
generated perform the appropriate diagnostic
procedures and repairs. Vehicle operation (engine,
transmission and vehicle lighting) may be affected if
DTCs are not serviced.
F/CMVSS, U.S. and Canadian RFI Requirements
1. All Ford vehicles built and fully completed by Ford
comply with F/CMVSS No. 108, “Lamps, Reflective
Devices and Associated Equipment” and other
applicable F/CMVSS that affect electrical
components. Care must be taken that modifications
do not conceal, alter or change components installed
or provided by Ford Motor Company to achieve this
conformance.
2. Incomplete vehicles (i.e., Chassis Cab, Stripped
Chassis, etc.) will conform to the F/CMVSS
according to the provisions and conditions stated in
the Incomplete Vehicle Manual (IVM) attached to
each incomplete vehicle.
3. Devices that emit radio frequency (RF) energy, such
as AM/FM radios and radio-controlled security
systems, marketed for sale or use in the United
States are subject to the rules and regulations of the
Federal Communications Commission (FCC) 47
CFR Parts 2 and 15.
These rules specify the following conditions of
operation:
This device complies with Part 15 of the FCC
Rules. Operation is subject to the following two
conditions:
(1) This device may not cause harmful interference,
and
(2) this device must accept any interference
received, including interference that may cause
undesired operation.
In addition, the FCC’s Rules may require the device
to be tested and found to comply with various RF
interference emission limits before it may be
marketed. The FCC establishes different limits
according to the particular use and installation of RF
devices. In some cases, a grant of equipment
authorization from the FCC also must be obtained
before any RF device may be marketed. Labeling
with certain FCC information may also be required.
To ensure continued compliance with the FCC’s
requirements, the owner, user, custom manufacturer,
or service technician must not modify or change the
RF device in a manner not expressly approved by
Ford Motor Company. Such modifications could void
the authority to operate the device.
4. All vehicles powered by spark ignition internal
combustion engines (e.g., gasoline or liquid
petroleum gas engines) and manufactured in
Canada or for sale or use in Canada are subject to
the Canadian “Regulations for the Control of
Interference to Radio Reception” per Interference-
Causing Equipment Standard (ICES-002) and
applicable test method according to “CAN/CSA-
C108.4-M06”. Violation of these regulations is
punishable by fine or imprisonment. Ford-built
incomplete vehicles other than stripped chassis are
designed and manufactured to be capable of
meeting the regulatory requirements or such
modifications thereof as may be authorized by the
Canadian Department of Communications. However,
because Ford has no control over how an
incomplete vehicle is completed by subsequent
stage manufacturers, Ford does not represent that
the completed vehicle incorporating the Ford-built
components
will
comply
with
applicable
requirements.
Routing & Clipping
1. It is strongly recommended that wiring in areas of
heavy rework, or in areas where welding operations
are to be performed, be removed prior to the rework
operations and reinstalled after the rework is
completed. The Instrument Panel (IP) cluster, Power
Control Module (PCM) and Body Control Module
(BCM) must be disconnected before any electrical
welding is performed, otherwise module damage
may result. If wire removal is not practical, the wires
must be shielded from damage due to the rework
and welding heat. All components and wiring should
be reinstalled as closely as possible to the way it
was installed before removal.
2. Wire routings of newly installed components or wire
routing revisions of the Ford harnesses necessitated
by reworks must conform to the following:
●
Wires routed through holes in sheet metal or
castings must have the hole edges protected by a
grommet.
●
Wires should be routed to avoid metal edges,
screws, trim fasteners and abrasive surfaces.
When such routings are not possible, protective
devices (shields, caps, etc.) must be used to
protect the wires and when wires must cross a
metal edge the edge should be covered with a
protective shield and the wiring fastened within 3
inches of the edge.
●
Wires must be routed to provide at least 3 inches
clearance to moving parts, unless positively
fastened or protected by a conduit.
●
Existing heat shields, insulation, and wire
shielding/twisting must be maintained.
●
Wire routings should avoid areas where
temperatures exceed 85° C [180° F] and a
minimum clearance of 231 mm [6 in] should be
maintained from exhaust system components.
Where compliance with this requirement is not
possible, high temperature insulation and heat
shields are required.
●
When wiring is routed between two members
where relative motion can occur the wiring should
be secured to each member, with enough wire
slack to allow flexing without damage to the wire.
●
Wiring to all circuit components (switches, relays,
etc.) in exposed locations must provide a drip loop
to prevent moisture from being conducted into the
device via the wire connection.
●
Routing wires into areas exposed to wheel wash
should be avoided. When such routings cannot be
avoided, adequate clipping or protective shields
are required to protect the wires from stone and
ice damage.
●
The wire retainers and grommets installed by the
assembly plant are usually designed to
accommodate only the Ford-installed wires.
Additional wiring or tubing should be retained by
additional clips. When added wires or tubes are
routed through sheet metal panels, new holes,
with proper wire protection and sealing, must be
used.
●
All wiring connections to components of the
factory-installed system must be accomplished by
using the proper mating wire termination.
(Connections on studs and ground connections
must use eyelet terminations, connections to
female bullets must terminate in male bullets, etc.)
Splice/Repair
When necessary to splice wire for repair or circuit
length revisions, the following guide should be followed:
●
Wire ends should be stripped making sure that
individual conductor strands are not damaged.
●
When soldering, make sure an adequate mechanical
joint exists before applying solder. Use only rosin
core solder — never acid core.
●
For crimp joints, use butt-type metal barrel fasteners
and a proper tool (such as Motorcraft crimp tool S-
9796) specifically designated for this type of work.
●
Splice joints must be adequately sealed and
insulated. Adhesive-lined heat shrink tubing is highly
recommended to cover soldered and bare metal
barrel crimp joints.
●
The most durable splice joint will be bare metal
barrel crimped, flow-soldered and covered with
adhesive lined heat shrink tubing. This is
recommended as the preferred splice joint.
●
The most durable splice joint will be bare metal
barrel crimped, flow-soldered and covered with
adhesive lined heat shrink tubing. This is
recommended as the preferred splice joint.
Circuit Protection
1. Modification to existing vehicle wiring should be
done only with extreme caution and consideration of
effects on the completed vehicle electrical system.
Anticipated circuitry should be studied to ensure that
adequate circuit protection will exist and that
feedback loops are not created.
2. Any added circuitry must be protected by a fuse or
circuit protection device installed by the bodybuilder.
3. Never drive additional electrical load directly from
the Body Control Module (BCM) output. The BCM
output must drive an auxiliary relay coil only. If you
try to drive an aftermarket electrical load directly, the
BCM will likely disable the output and you may have
to replace the BCM.
4. Never increase the rating of a factory installed fuse
or circuit breaker.
5. For added lamp loads, the “Bulb Chart” on a
following page will aid in determination of common
lamp current draws.
6. It is the body builder’s responsibility to use sound
engineering judgment when making any
modifications to a vehicle, and the body builder is
responsible for ensuring that all modifications made
are appropriate for the intended vehicle application.
Guidelines for Powertrain Control System
Application
All Powertrain Control Module (PCM) wiring, in
particular the 12A581 and 14401, must be a minimum
of 51 mm [2 in] from secondary ignition coil wires and at
least 102 mm [4 in] from the distributor, ignition coil
tower, starter motor and starter motor wiring as well as
102 mm [4 in] from the alternator output wiring. These
clearances apply in particular to all PCM sensor and
actuator pigtail wiring. PCM wires shall not be in the
same bundle as other high-current non-PCM circuits
(e.g., tachometer wire from coil to Thick Film Ignition
Module (TFI), power seat/ door lock/window, horn,
alternator regulator) for a distance of more than 20
inches.
NOTE: The final stage manufacturer is responsible for
ensuring that the final vehicle configuration
meets all applicable regulatory requirements.
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215
ELECTRICAL WIRING
GENERAL PRACTICES
ADDITION OF LIGHTS OR ELECTRICAL DEVICES (Cont'd)
Body Builders Layout Book
4
ELECTRICAL WIRING
2013
MODEL YEAR
www.fleet.ford.com/truckbbas
Modern Ford vehicle electronic controls provide
Ford customers with superior reliability and
diagnostic capability when vehicle modifications
are performed in line with the recommendations
detailed here. Many traditional modification
methods may no longer be compatible with these
modern electronic modules.
Although there are many points in the truck
electrical system to connect additional circuits
certain connection points are recommended for
reliability and convenience. This section defines the
recommended connection points for each Ford
Truck model and the maximum electrical loads
allowable.
CAUTION: Improper electrical tie-ins may affect
vehicle operation (i.e., engine, transmission,
lighting).
After all electrical or vehicle modifications, perform
the on-board diagnostics procedures as described
in the powertrain control/emissions diagnosis
manual to clear all diagnostic trouble codes (DTCs).
In addition, perform self-test to the BCM and test all
lighting outputs. Road test vehicle and rerun the
on-board diagnostics to verify that no DTCs are
present. If DTCs are generated, perform the
appropriate diagnostic procedures and repairs.
Vehicle operation (engine, transmission, lighting)
may be affected if DTCs are not serviced.
Alternative connections or wiring practices are not
recommended as these modifications will result in
other circuits becoming non-functional. Disconnect
the battery negative (ground) cable and remove it
from the battery carrier prior to any vehicle
modification. Upon completion of body or
equipment installation, all wiring should be
checked for proper routing, etc. to preclude
electrical shorts upon re-installation of the battery
negative cable. Do not splice into the Powertrain
System (PCM-V). Connecting to any component or
wires to this system may adversely affect
engine/transmission operation. Likewise, do not
splice into any lighting circuits as this may
permanently disable the lighting circuits within the
Body Control Module (BCM). Proper modification
practices are fully described in this layout book.
LIGHTS CONTROLLED BY HEADLAMP SWITCH
●
Super Duty F-Series
The headlamp switch used on the Super Duty F-Series
vehicles is a low current switch designed to signal the
Body Control Module (BCM) to activate all exterior
lighting. The left-hand and right-hand low beam lamps
are then fused individually using 10A fuses located in
the BCM fuse box. The high beam lamps are fused
using a separate 15A fuse while the interior lamps are
fused using 10A fuses located in the BCM fuse box. A
connection to any circuit in the system controlled by the
headlamp switch must be done using an auxiliary relay.
Any connection must be performed on the lighting
output of the BCM. Additional loads connected to the
headlamp switch will damage the headlamp switch.
A park lamp relay circuit CLS30 for SUB additions is
provided for convenience as standard equipment on
chassis cabs, optional on pickups. Do not connect to
other OEM wires.
●
E-Series
Rear Lights — Splice into circuit CLS 30 VT/WT in
crossover harness at rear of vehicle.
Front Lights — Splice into circuit CLS 30 VT/WT in
engine compartment 12A581 wire
assembly along right or left fender
apron.
LIGHTS CONTROLLED BY STOP LAMP
SWITCHAND TURN INDICATOR SWITCH
NOTE: Splicing into the stop lamp switch can damage
the Body Control Module (BCM). Splicing into the stop
lamp switch on vehicles with Electronically Controlled
Transmissions can interfere with the proper functioning
of PCM, speed control, and anti-lock brake electronic
modules. This can:
●
Affect EFI engine idle speed quality.
●
Prevent the Powertrain Control Module (PCM)
controlled torque converter clutch from applying at
throttle openings less than half-throttle.
●
Deactivate anti-lock brake system operation.
●
Prevent the speed control from disengaging upon
braking.
Do not delete or deactivate the Center High Mount Stop
Lamp (CHMSL) unless it will be blocked by second unit
body.
The stop lamp switch that is in use on Ford trucks is a
mechanical switch operated by brake pedal. The BCM
supports adding loads to the brake pedal switch
through fuse 31 at pins C6-19 and C2-4. Tapping into
other BCM inputs, such as Park Brake and Door Ajar,
can cause BCM failure. Under no circumstances are
additional brake pedal loads to be added by directly
splicing into vehicle wiring.
F-150, SUPER DUTY F-SERIES AND E-SERIES
MODELS
Ford trucks are released with a mechanical stop lamp
switch mounted on the brake pedal arm for E-Series
and mounted on the pedal pin and master cylinder push
rod for F-150 and Super Duty F-Series. If only stop
lamp function is desired for the added lights, connect to
circuit YE-GN CLS43 at the blunt cut customer access
wire located at the rear of the vehicle near trailer tow
connector C4099.
The turn signal switch is designed to use a low current
to signal the BCM to activate turn signal and stop
lamps. The switch is not designed to directly power any
lamps or other electrical devices.
If both turn signal and stop lamp function are desired
for the added lights, splice into Super Duty F-Series
trailer tow wiring provided with the vehicle. These
circuits are provided as standard equipment and are
located at the rear of the vehicle. Do not splice into
turn/stop circuits at the BCM or turn circuits at the multi-
function switch. Splicing in those areas will damage the
switch or cause the BCM to malfunction. Use the trailer
tow circuits and trailer tow relays to power added
turn/stop lights. Circuits are accessible at the rear of the
vehicle; LT/Stop=YE, RT/Stop=GN.
Reverse/back-up lights must be tied-in using trailer tow
relays and circuits in same manner as turn/stop lights.
ADDED LIGHTS OR ACCESSORIES CONTROLLED
BY ADDED SWITCHES
This section describes the connection points for added
electrical accessories when these accessories are to be
controlled by added switches not a part of the Ford-
released vehicle. The added switches and wiring must
have sufficient electrical capacity for the accessory load
and must be tied to the battery using separate fuses
and a circuit protection device. Additional loads on Ford
provided fuses may cause permanent BCM damage
and lighting failure. Also, added current draw must not
cause total loads to exceed capabilities of the base
vehicle wiring.
WIPER DELAY MODULE – E-SERIES, F-53 & F-59
STRIPPED CHASSIS
The Wiper Delay Module is not internally protected for a
continuous high current load greater than 9 amps and
must be protected either internal to the wiper motor or
via inline protection such as a properly sized circuit
breaker. The existing 30 amp fuse in the fuse panel is
sized for the maximum allowable in-rush current and
does not provide appropriate protection to the Wiper
Delay Module.
MALFUNCTION INDICATOR LIGHT (MIL)
The “Malfunction Indicator Light” is used to indicate
malfunctions of the engine’s emission control system
and certain powertrain emissions-related components.
For all incomplete vehicles, except Basic (Stripped)
Chassis (which is not equipped with an instrument
panel), the MIL is Ford-installed and operational in the
instrument panel. The E-Series Basic (Stripped)
Chassis vehicle has the MIL warning light installed in
the instrument cluster, which is shipped in the dunnage
box.
If an alternate instrument cluster is utilized, the final
stage manufacturer must install an operational MIL in
the instrument cluster. The MIL must be located on the
driver’s-side instrument panel, be of sufficient
illumination and location to be readily visible under all
lighting conditions and shall be amber in color when
illuminated. The MIL, when illuminated, shall display the
phrase “Check Engine” or “Service Engine Soon”. The
word “Powertrain” may be substituted for “Engine” in
the previous phrases. Alternatively, the ISO engine
symbol may be substituted for the word “Engine” or for
the entire phrase. This is a requirement for emission
certification.
Once the light has been completed by the final stage
manufacturer, proper function can be determined by
turning the key to the on position. The light should
come on prior to engine cranking and go out when the
engine starts.
RADIO FREQUENCY INTERFERENCE (RFI)
During modifications to the vehicle, manufacturers,
service technicians, owners and users should take the
necessary precautions to maintain the RFI integrity of
components. Both the United States and Canada have
RFI regulation in effect. For any completed vehicle,
additional measures may be needed to adequately
suppress RFI emissions. Affected components could
include spark plugs, ignition wires, ignition coils, ground
straps, ignition components shields, accessory drive
belts, ignition coil suppressors, the Powertrain Control
Module (PCM) and the Body Control Module (BCM).
Guidance for installing two-way mobile radios can be
found via the web at www.fordemc.com/docs
download/Mobile_Radio_Guide.pdf
.
(Cont'd next page)
Additional Electrical information
can be accessed via the web at:
www.fleet.ford.com/truckbbas
under the “Bulletins” tab.
NOTE: The final stage manufacturer is responsible for
ensuring that the final vehicle configuration
meets all applicable regulatory requirements.
304
ELECTRICAL WIRING
GENERAL PRACTICES
ADDITION OF LIGHTS OR ELECTRICAL DEVICES (Cont'd)
Body Builders Layout Book
5
ELECTRICAL WIRING
2013
MODEL YEAR
www.fleet.ford.com/truckbbas
Additional Electrical information
can be accessed via the web at:
www.fleet.ford.com/truckbbas
under the “Bulletins” tab.
NOTE: The final stage manufacturer is responsible for
ensuring that the final vehicle configuration
meets all applicable regulatory requirements.
Wire Gage
Maximum Current Capacity
(Plastic Insulated Copper Wire)
20
10 Amps
18
15 Amps
16
20 Amps
14
25 Amps
12
30 Amps
10
40 Amps
WIRE GAGE TABLE
BULB
TRADE
NUMBER
CANDLE
POWER
CURRENT @
RATED
VOLTAGE
67/97
4
0.69 A @ 13.5V
168
3
0.35 A @ 14.0V
192
3
0.33 A @ 13.0V
194
2
0.27 A @ 14.0V
211-2
12
0.97 A @ 12.8V
212-2
6
0.74 A @ 13.5V
578
9
0.78 A @ 12.8V
579
9
0.8 A @ 12.8V
904
4
0.69 A @ 13.5V
904NA
5.3
0.69 A @ 13.5V
906
6
0.69 A @ 13.5V
912
12
1.0 A @ 12.8V
916
2
0.54 A @ 13.5V
916NA
1.5
0.54 A @ 13.5V
921
21
1.4 A @ 12.8V
922
15
0.98 A @ 12.8V
1157A (major)
24
2.1 A @ 12.8V
1157A (minor)
2.2
0.59 A @ 14.0V
3057 (major)
32
2.1 A@ 12.8V
3057 (minor)
32
2.1 A @ 12.8V
3057K (major)
32
2.1 A @ 12.8V
BULB
TRADE
NUMBER
CANDLE
POWER
CURRENT @
RATED
VOLTAGE
3057K (minor)
2
0.48 A @ 14.0V
3155K
21
1.6 A @ 12.8V
3156 (P27W)
32
2.1 A @ 12.8V
3157 (P27/2W) (major)
32
2.1 A @ 12.8V
3157 (P27/2W) (minor)
3
0.59 A @ 14.0V
3157A (major)
24
2.1 A @ 12.8V
3157A (minor)
2.2
0.59 A @ 14.0V
3157K (major)
32
2.1 A @ 12.8V
3157K (minor)
3
0.59 A @ 14.0V
3456K
40
2.23 A @ 12.8V
3457AK (major)
30
2.23 A @ 12.8V
3457AK (minor)
2.2
0.59 A @ 14.0V
3457K (major)
40
2.23 A @ 12.8V
3457K (minor)
3
0.59 A @ 14.0V
3757AK (major)
24
2.1 A @ 12.8V
3757AK (minor)
2.2
0.59 A @ 14.0V
4057K (major)
32
2.23 A @ 12.8V
4057K (minor)
2
0.48 A @ 14.0V
4157K (major)
32
2.23 A @ 12.8V
4157K (minor)
3
0.59 A @ 14.0V
W5W
4
0.4 A @ 12.0V
HALOGEN
BULB
TRADE
NUMBER
CANDLE
POWER
WATTS @
RATED
VOLTAGE
H1
117
55W @ 12.0V
H3
121
55W @ 12.0V
HB2 (9003) (low)
76
55W @ 12.0V
HB2 (9003) (high)
125
60W @ 12.0V
9005 (HB3)
135
65W @ 12.8V
9006 (HB4)
80
55W @ 12.8V
9007 (HB5) (low)
80
55W @ 12.8V
9007 (HB5) (high)
107
65W @ 12.8V
H13/9008 (low)
—
55W @ 12.8V
H13/9008 (high)
—
65W @ 12.8V
H7
125
55W @ 12.0V
H9
167
65W @ 12.0V
H11
107
55W @ 12.8V
H6054 (low)
—
55W @ 12.8V
H6054 (high)
—
65W @ 12.8V
9140
48
40W @ 12.8V
9145 (H10)
65
45W @ 12.8V
BULB CHARTS
ELECTRICL LOAD LIMITATIONS
If the total electrical load on a factory circuit, after the
addition of electrical equipment, is less than 80% of the
fuse or circuit breaker protection rating in that circuit or
less than the capacity of some limiting component
(switch, relay, etc.), the items to be added can be
connected directly to that circuit. For fuses located in
the engine compartment, the electrical load should not
exceed 60% of the fuse or circuit breaker protection
rating. If the total electrical load to be added on a
factory circuit exceeds the value of the circuit
protection, or the value of some limiting component, the
items to be added cannot be added directly to the
circuit.
●
Additional loads cannot be driven by the Body
control Module (BCM), they must be driven by an
auxiliary relay. The coil of the relay can be fed from
the factory wiring (now acting as a signal circuit) with
the added wiring providing the power feed to the
added electrical device through the relay power
contacts. (The relay selection is important and
depends on current requirements, number of cycles
expected in the relay lifetime, whether the relay is to
be operated intermittently or for long periods of time,
and whether the relay is exposed to weather
conditions or is installed in a protected area. When
the current requirements of a circuit exceed the
capacity of an available relay, more than one relay
can be used if the circuit is wired to split the load).
●
The factory wiring should not be used as a power
feed to the relay power contacts or switches. Battery
power is to be supplied from the starter motor
solenoid positive terminal for added circuits requiring
a maximum of 30 amps or directly from the battery
positive terminal for added circuits requiring
greater than 30 amps of current.
Caution: Never use the stud on the underhood fuse
panel as a junction point.
Circuit protection (fuses or circuit breakers) must be
provided for all added wiring. The protection device
rating should not exceed the current requirements for
the add-on components and should be installed as
close to the point of tapped power as possible.
Wire Gage
1. When adding wiring, the wire gage size should be
determined as follows:
●
Where wire is spliced to extend a circuit, the
added wire should have a gauge at least that of
the circuit being lengthened.
●
When wire is being added to feed add-on devices,
the Wire Gage Table on this page should be used.
NOTE: The current capacity of a given wire varies
with temperature and type of insulation. The table,
however, represents generally accepted values as a
guide.
2. All added underhood or underbody wiring should
have a thermostat insulation (such as Hypalon or
Cross-linked polyethylene).
The following specifications typically apply:
●
SAE specifications J1128 type SXL, GXL or TXL
except for battery cables
●
SAE specifications J1127 type SGX or STX for
battery cables.
100
ELECTRICAL WIRING
E-SERIES
CHASSIS CIRCUITS
Body Builders Layout Book
6
ELECTRICAL WIRING
2013
MODEL YEAR
www.fleet.ford.com/truckbbas
UNWRAP TAPE FROM
HARNESS IN THIS AREA
AND REMOVE JUMPER
CONNECTION TO EXPOSE
FRONT OF
VEHICLE
THE “CHMSL” ELECTRICAL CONNECTION FOR A
STRIPPED CHASSIS IS PROVIDED IN A DETAILED
SCHEMATIC WHICH IS PACKAGED WITH THE
BODY BUILDER ELECTRICAL CONNECTORS.
TO INSTALL
THE “CHMSL CONNECTOR” .
“
CHMSL”
Circuit
Number
Color
Code
Wire
Gauge
Functional Description
CAT 19
BU
12
Electric trailer brake controller to trailer
CAT 14
OG
10
Relay feed ignition run
SBB 18
YE-RD
12
Trailer brake controller or B+ feed
CAT 06
YE
18**
Fused left hand stop/turn
CAT 09
GN
18**
Fused right hand stop/turn
CAT 08
W
14*
Ground
CLS 43
LG
18
Center high mount or lamp feed stop
CAT 17
BR
14
Relay feed marker lamps
CAT 03
GY-BN
12
Relay feed backup lamps
CAC 17
VT-GY
12
Customer pass-thru circuits
CAC 18
YE-GY
12
Customer pass-thru circuits
VLN 33
BK-LB
18
Courtesy lamps
CLN 09
YE-GN
18
Courtesy switch feed
CLS 18
GY-BN
18
Left stop/turn rear signal
CLS 19
VT-OG
18
Right stop/turn rear signal
GD116
BK-VT
16
Electric brake controller ground
E-SERIES SUPER DUTY
CUTAWAY / STRIPPED CHASSIS
*
10 for 7-pin Trailer Tow Connector
**
14 for 7-pin Trailer Tow Connector
115
ELECTRICAL WIRING
E-SERIES
UPFITTER SWITCHES
Body Builders Layout Book
7
ELECTRICAL WIRING
2013
MODEL YEAR
www.fleet.ford.com/truckbbas
REF - 12A581
ENG CMPT WIRING
Additional Notes: All recommended wire lengths are for direct feeds only. To compensate for connector and/or switch
contact resistance, subtract the following from the recommended wire lengths:
1. Subtract 1 foot per connection for 14 awg or smaller diameter and 3 feet for 12 awg or larger diameter.
2. Subtract 3 feet per switch connection for all wire awgs.
TO BLUNT CUT
FRONT OF VEHICLE
AUX 1
AUX 2
AUX 3
AUX 4
POWER OUTPUT RELAY 1X
POWER OUTPUT RELAY 2X
POWER OUTPUT RELAY 3X
POWER OUTPUT RELAY 4X
POWER INPUT
BACKLIGHT INPUT
GROUND
F42
10A
HOT in
RUN
IP JUNCTION BOX
F19
30A
UPFITTER 1
F20
30A
UPFITTER 2
F44
10A
UPFITTER 3
F45
15A
UPFITTER 4
YE
GN-BN
VT-GN
BN
85
62
8
7
2
8
3
1
5
6
7
PRIMARY
BATTERY
CUSTOMER ACCESS (UPFITTER)
SCHEMATIC
UPFITTER
SWITCHES
BLUNT CUT WIRES
UPFITTER CIRCUITS
14 AWG
60
-
15
15
12 AWG
-
-
25
25
10 AWG
-
-
35
35
WIRE LENGTH (FEET)
RECOMMENDED MAX ALLOWABLE
Circuit Color
BROWN
VIOLET-GREEN
GREEN-BROWN
YELLOW
Code
BN
VT-GN
GN-BN
YE
Max Continuous Load
10A
7A
21A
21A
18 AWG
25
50
-
-
16 AWG
35
70
-
-
Description
UPFITTER 4
UPFITTER 3
UPFITTER 2
UPFITTER 1
349
ELECTRICAL WIRING
E-SERIES
CUSTOMER ACCESS CIRCUITS
Body Builders Layout Book
8
ELECTRICAL WIRING
2013
MODEL YEAR
www.fleet.ford.com/truckbbas
(Cont'd next page)
REF - 12A581 WIR ASY
ENG CMPT WIRING
REF - 12A581 WIR ASY
ENG CMPT WIRING
FRONT OF VEHICLE
9C24-14A411-J CONNECTOR # ENG - 2
BLACK CONNECTOR & PIGTAIL ASY
MATES TO CIRCLED BLACK CONNECTOR
(INTERVAL WIPER/WASHER)
BC24-14A411-H CONNECTOR # ENG-1
BLACK CONNECTOR & PIGTAIL ASY
MATES TO CIRCLED BLACK CONNECTOR
(FRONT LAMPS)
ENGINE CONNECTOR (9C24-14A411-J)
14 AWG
-
-
-
-
-
30
-
-
30
30
37
WIRE LENGTH (FEET)
RECOMMENDED MAX ALLOWABLE
CIRCUIT COLOR
GREY-BROWN
VIOLET-ORANGE
GREEN-VIOLET
VIOLET-WHITE
BLUE-ORANGE
RED
YELLOW
BLACK-BLUE
BLACK-GREY
BLACK-GREY
BLUE-WHITE
CODE
GY-BN
VT-OG
GN-VT
VT-WH
BU-OG
RD
YE
BK-BU
BK-GY
BK-GY
BU-WH
MAX CONTINUOUS LOAD
250 milliamperes**
250 milliamperes**
250 milliamperes**
250 milliamperes**
250 milliamperes**
15A
3A
3A
See Note K
See Note K
See Note C
** Max total of < 1A
18 AWG
20
20
20
20
20
-
20
20
-
-
18
16 AWG
-
-
-
-
-
-
-
-
-
-
21
DESCRIPTION
CRW07 WASHER SIGNAL
CRW08 WIPER HIGH
CRW17 Intermittent A
CRW18 Intermittent B
CRW19 Intermittent C
SBB49 RUN-ACC FUSED POWER
CBP45 RUN-ACC FUSED POWER
GD114 GROUND - LOGIC
GD123 GROUND - WIPER
GD123 GROUND - WASHER
CLS28 BACK-UP LAMP
ENGINE CONNECTOR (9C24-14A411-H)
14 AWG
NOT FUSED
85
85
85
85
85
85
12 AWG
-
-
-
-
-
-
-
10 AWG
-
-
-
-
-
-
-
WIRE LENGTH (FEET)
RECOMMENDED MAX ALLOWABLE
CIRCUIT COLOR
BLACK-GREY
VIOLET-WHITE
YELLOW-VIOLET
BROWN-BLUE
BLUE-GREEN
BLUE-GREEN
YELLOW-VIOLET
CODE
BK-GY
VT-WH
YE-VT
BN-BU
BU-GN
BU-GN
YE-VT
MAX CONTINUOUS LOAD
21A
See Note E
10.2A
4.3A
4.3A
2.2A
2.2A
18 AWG
-
-
33
33
33
33
33
16 AWG
-
50
50
50
50
50
50
DESCRIPTION
GD123 GROUND
CLS30 PARK LAMP
CLF08 HIGH BEAMS
CLF04 LT LOW BEAM
CLF05 RT LOW BEAM
CLS21 LT FRONT TURN
CLS25 RT FRONT TURN
ENG-1
C11-F
ENG-2
C22-B
CAV
8
1
2
3
7
6
5
CAV
4
6
5
2
10
1
3
7
8
16
9
GROUND - WIPER
(BLACK-GREY)
GROUND - WASHER
(BLACK-GREY)
GROUND - LOGIC
(BLACK-BLUE)
WIPER HIGH
(VIOLET-ORANGE)
Intermittent A
(GREEN-VIOLET)
WASHER SIGNAL
(GREY-BROWN)
Intermittent C
(BLUE-ORANGE)
RUN-ACC FUSED POWER
(YELLOW)
Intermittent B
(VIOLET-WHITE)
RUN-ACC FUSED POWER
(RED)
BACK-UP LAMP
(BLUE-WHITE)
NOTE A:COMBINED LOAD < 5A
NOTE B:COMBINED LOAD WITH OTHER SWITCH ILLUMINATION < 2A
NOTE C:COMBINED LOAD WITH TRAILER TOW BACKUP < 10A
NOTE D:COMBINED LOAD < 14A
NOTE E:COMBINED LOAD < 10A
NOTE F:COMBINED LOAD WITH OTHER BATTERY SAVE / DEMAND LAMPS < 6A
NOTE H:COMBINED LOAD < 4.8A
NOTE J: : COMBINED LOAD < 4.8A
NOTE K:COMBINED LOAD < 21A
NOTE L:WIRES HAVE LABELS
NOTE M:CONNECTOR VIEWS ARE MATING VIEWS, NOT WIRE ENTRY SIDE
* CCB08 is 18 AWG, CLS30 is 16 AWG
Additional Note:
All recommended wire lengths are for direct feeds only. To compensate for connector
and/or switch contact resistance, subtract the following from the recommended wire
lengths:
1. Subtract 1 foot per connection for 14 awg or smaller diameter and 3 feet for 12 awg
or larger diameter.
2. Subtract 3 feet per switch connection for all wire awgs.
ENGINE MODIFIER CONNECTOR (9C24-14A411-A)
CIRCUIT COLOR
YELLOW-ORANGE
VIOLET-GREY
YELLOW-GREY
GREEN-RED
CODE
YE-OG
VT-GY
YE-GY
GN-RD
DESCRIPTION
CAC14 RUN / START FUSED FEED
CAC17 PASS THRU (I/P)
CAC18 PASS THRU (I/P)
SBB68 BATTERY FUSED FEED
MAX CONTINUOUS LOAD
See Note A
25A
25A
See Note B
14 AWG
-
-
-
-
12 AWG
28
NOT FUSED
NOT FUSED
-
10 AWG
45
-
-
30
WIRE LENGTH (FEET)
RECOMMENDED MAX ALLOWABLE
NOTE A:
COMBINED LOAD < 25A
NOTE B:
COMBINED LOAD < 35A
NOTE C:
COMBINED LOAD WITH TRAILER TOW BACKUP < 10A
NOTE D:
COMBINED LOAD < 14A
NOTE E:
COMBINED LOAD < 4.8A WITH OTHER LT STOP/TURN CIRCUITS
NOTE F:
COMBINED LOAD < 4.8A WITH OTHER RT STOP/TURN CIRCUITS
NOTE G:
COMBINED LOAD < 10A WITH OTHER PARK LAMPS
NOTE H:
COMBINED LOAD < 6A WITH OTHER BATTERY SAVER/DEMANDS LAMPS CIRCUITS
NOTE J:
COMBINED LOAD < 5A WITH OTHER STOP LAMP CIRCUITS
* CCB08 is 18 AWG, CLS30 is 16 AWG
Additional Note:
All recommended wire lengths are for direct feeds only. To compensate for connector and/or switch
contact resistance, subtract the following from the recommended wire lengths:
1. Subtract 1 foot per connection for 14 awg or smaller diameter and 3 feet for 12 awg or larger diameter.
2. Subtract 3 feet per switch connection for all wire awgs.
CAV
1
2
3
4
9C24-14A411- A
DARK GREY CONNECTOR & PIGTAIL ASY
MATES TO CIRCLED CONNECTOR
FRONT OF
VEHICLE
PASS THRU TO I/P
(VIOLET-GREY)
RUN / START FUSED FEED
(YELLOW-ORANGE)
BATTERY FUSED FEED
(GREEN-RED)
PASS THRU TO I/P
(YELLOW-GREY)
REF - 12A581 WIR ASY
ENG CONTR SNS
VIEW OF FRONT END ENGINE COMPARTMENT (LH SIDE)
(GAS VEHICLE SHOWN – DIESEL SIMILAR)
RT FRONT TURN
(YELLOW-VIOLET)
LT FRONT TURN
(BLUE-GREEN)
GROUND
(BLACK-GREY)
PARK LAMP
(VIOLET-WHITE)
HIGH BEAMS
(YELLOW-VIOLET)
LT LOW BEAM
(BROWN-BLUE)
RT LOW BEAM
(BLUE-GREEN)
339
ELECTRICAL WIRING
E-SERIES
CUSTOMER ACCESS CIRCUITS (Cont'd)
Body Builders Layout Book
9
ELECTRICAL WIRING
2013
MODEL YEAR
www.fleet.ford.com/truckbbas
(Cont'd next page)
I/P MODIFIER CONNECTOR (9C24-14A411-G)
14 AWG
-
-
-
-
50
50
12 AWG
25
NOT FUSED
NOT FUSED
-
-
-
10 AWG
50
-
-
30
-
-
WIRE LENGTH (FEET)
RECOMMENDED MAX ALLOWABLE
CRKT. COLOR
YELLOW-ORANGE
VIOLET-GREY
YELLOW-GREY
GREEN-RED
BLUE-GREEN
YELLOW-VIOLET
CODE
YE-OG
VT-GY
YE-GY
GN-RD
BU-GN
YE-VT
MAX CONTINUOUS LOAD
See Note A
25A
25A
See Note B
200 milliamps
200 milliamps
18 AWG
-
-
-
-
50
50
16 AWG
-
-
-
-
50
50
DESCRIPTION
CAC14 RUN / START FUSED FEED
CAC17 PASS THRU (I/P)
CAC18 PASS THRU (I/P)
SBB68 BATTERY FUSED FEED
CLS21 LT FRONT TURN SIGNAL / HAZ
CLS25 RT FRONT TURN SIGNAL / HAZ
CAV
4
1
2
3
5
6
9C24-14A411-G
GREY CONNECTOR & PIGTAIL ASY
BATTERY FUSED FEED
(GREEN-RED)
PASS THRU (I/P)
(YELLOW-GREY)
PASS THRU (I/P)
(VIOLET-GREY)
RT FRONT TURN SIGNAL / HAZ
(YELLOW-VIOLET)
LT FRONT TURN SIGNAL / HAZ
(BLUE-GREEN)
RUN / START FUSED FEED
(YELLOW-ORANGE)
TO 14405
WIR ASY
TO 14401
WIR ASY
TO SPDJB
TO STP LP SW
FRONT OF
VEHICLE
TO 14401
WIR ASY
REF - 12A581 WIR ASY
ENG CONTR SNS
I/P DRIVER SIDE
B-PILLAR MODIFIER CONNECTOR (9C24-14A411-E)
CRKT. COLOR
YELLOW-ORANGE
BLACK
WHITE-RED
GREEN-RED
CODE
YE-OG
BK
WH-RD
GN-RD
DESCRIPTION
CAC14 RUN / START FUSED FEED
GD133 GROUND
SBB15 BATTERY FUSED FEED
SBB68 BATTERY FUSED FEED
MAX CONTINUOUS LOAD
See Note A
40A
25A
See Note B
14 AWG
-
-
-
-
12 AWG
25
-
25
-
10 AWG
50
NOT FUSED
50
30
WIRE LENGTH (FEET)
RECOMMENDED MAX ALLOWABLE
CAV
5
1
6
3
FRONT OF
VEHICLE
REF - 14405 WIR ASY
TO 14335 WIR ASY
TO 14C719 WIR ASY
TO MODIFIED VEH
REF - 9C24-14A411-E
TO MODIFIED VEH
TO MODIFIED VEH
13A427 - PIA 14405 WIR ASY
9C24-14A411-E
GREY CONNECTOR & PIGTAIL ASY
MATES TO CIRCLED CONNECTOR
B-PILLAR
BATTERY FUSED FEED
(GREEN-RED)
GROUND
(BLACK)
BATTERY FUSED FEED
(WHITE-RED)
RUN / START FUSED FEED
(YELLOW-ORANGE)
B-PILLAR DRIVER SIDE
9C24-14A411-G
Hot in
RUN or
START
F52
10A
F77
10A
Primary
Battery
F30
10A
F12
40A
F28
20A
F15
40A
F51
20A
F68
50A
PCM
5R transmission
4R transmission
Trans Range Sensor
STOP
LAMP SW
IP JUNCTION BOX
F22
15A
F25
10A
Park
Lamps
BATT
SAVER
CENTER
HIGH
MOUNTED
STOP LAMP
LT FRONT
TURN /
HAZARD
RT FRONT
TURN /
HAZARD
9C24-14A411-A
9C24-14A411-E
9C24-14A411-F
BU-RD (SBB51)
YE-GN (CLN09)
BU-WH (CLS28)
VT-WH (CCB08)
GY-BN (CLS18)
VT-OG (CLS19)
VT-WH (CLS30)
BK (GD117)
1
2
3
4
5
6
7
8
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
BK (GD133)
YE-OG (CAC14)
WH-RD (SBB15)
GN-RD (SBB68)
VT-GY (CAC17)
YE-GY (CAC18)
YE-OG (CAC14)
BU-GN (CLS21)
YE-VT (CLS25)
GN-RD (SBB68)
1
2
3
4
3
4
1
2
GN-RD (SBB68)
VT-GY (CAC17)
YE-OG (CAC14)
YE-GY (CAC18)
LT BACK UP
LAMP
F58
15A
RT BACK UP
LAMP
To Trailer Tow
Backup Lamps
To Dome Lamps
To Park Lamps / Side
Markers / License Lamp
LT STOP /
TURN /
HAZARD
RT STOP /
TURN /
HAZARD
1
2
3
4
5
6
7
8
BK
YE-OG
WH-RD
GN-RD
BU-RD
YE-GN
BU-WH
VT-WH
GY-BN
VT-OG
VT-WH
BK
GN-RD
YE-VT
BU-GN
YE-OG
YE-GY
VT-GY
VT-GY
YE-OG
YE-GY
GN-RD
CUTAWAY ONLY
39
9
MODIFIED VEHICLE SCHEMATIC
119
ELECTRICAL WIRING
E-SERIES
CUSTOMER ACCESS CIRCUITS (Cont'd)
Body Builders Layout Book
10
ELECTRICAL WIRING
2013
MODEL YEAR
www.fleet.ford.com/truckbbas
F22
15A
Primary
Battery
STRIPPED CHASSIS
FRONT LIGHTING SCHEMATIC
F23
15A
IP JUNCTION
BOX
Park
Lamps
High
Beams
TO 9C24-13A718-A
TO 9C24-14A411-F
BC24-14A411-H See notes L and M
YE-VT
VT-WH
STRIPPED CHASSIS
WIPER SCHEMATIC
Primary
Battery
F49
30A
F45
5A
Hot in
RUN or
ACC
IP JUNCTION BOX
WIPER SWITCH
1
8
16
1
8
16
2
3
4
5
6
7
10
2
3
4
5
6
7
10
BK-GY (GD123)
BK-GY (GD123)
BK-BU (GD114)
VT-OG (CRW08)
GN-VT (CRW17)
GY-BN (CRW07)
YE (CBP45)
VT-WH (CRW18)
BU-OG (CRW19)
RD (SBB49)
BU-WH (CLS28)
9C24-14A411-J See notes L and M
BK
BK
BK
VT-OG
GN-VT
GY-BN
YE
VT-WH
BU-OG
VT-WH
3
9
9
FROM STRIPPED
CHASSIS SCHEMATIC
BU-WH
1
2
3
4
5
6
8 7
VT-WH (CLS30)
YE-VT (CLF08)
BN-BU (CLF04)
BLOCKED
BK-GY (GD123)
BU-GN (CLF05)
BU-GN (CLS21)
YE-VT (CLS25)
LT LOW BEAM
RT LOW BEAM
LT FRONT TURN / HAZARD
RT FRONT TURN / HAZARD
BN-BU
BU-GN
YE-VT
BU-GN
1 2 2 3
4
5 6 6 7
8
GROUND
BLOCKED
BK-GY
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