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1999 Model Year Ford Light Truck
"What's New" Manual

 


F-Series / Econoline

Ford Motor Company / Truck Vehicle Center / Special Vehicle Engineering Department

The purpose of this manual is to provide some advance insight into 1999 model year Ford Light Truck product features that may assist final stage manufacturers, and vehicle alterers, in preparing their production process.

This manual is for reference only, reflecting information available as of August, 1998, 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.

Light Truck Body Builders Layout Book

Incomplete Vehicle Manual

Ford Truck Source Book

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.

Table of Contents

Body Builder 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 the Truck Vehicle Center.

Truck Body Builder Advisory Service
Provides daily technical assistance

Modiefied Vehicle Engineering & Quality Programs
Responsible for qualifying the engineering process control capability of final stage  manufacturers under these programs:

      • QVM–Ambulance Quality Program (voluntary)
      • QVM–Motor Home & Transit Bus Quality Program (voluntary)
      • Conversion Van Quality Program
      • F-Series Quality Program

MVE Ship-Thru Section
Responsible for qualifying the engineering process control capability of companies that up-fit vehicles in the ship-thru delivery process.

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1999 Model Year Assembly Plant Job #1 Timing

Vehicles Assembly Plant Job #1
F150/250
Norfolk Assembly Plant
03-Aug-1998
 
Michigan Truck Plant
16-Aug-1998
 
Kansas City A.P.
24-Aug-1998
 
Ontario Truck Plant
31-Aug-1998
Super Duty F-Series  
05-Jan-1998
F250/350/450/550:
Kentucky Truck Plant
03-Aug-1998
F650/750:
Kentucky Truck Plant
15-Mar-1999
F53 Class A Motor Home Chassis:
IMMSA / Mexico
07-Sep-1998
Econoline
Lorain Assembly Plant
10-Aug-1998

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F-150/250
(under-8500 lb. GVWR)

New Models and Packages

  • Standard 4-Door Super Cab.
  • Ford SVT F-150 "Lightning" Sport Truck available 1999-1/2 (3/1/99).
  • New RPO XL and XLT Sport Packages, marketed as "4x4 XLT Sport Group", available on F150 models approximately 10/1/1998, replacing the Off-Road Appearance Package.

Powertrain

  • 5.4L gets an increase of 25 horsepower to 250 hp / 345 lb.-ft torque.
  • Manual transmission shift lever moved rearward 55 mm, and gets a new rubber boot.
  • An upgraded 4R70W automatic transmission replaces the 4R100 for F150 5.4L engine in 49-States and High Altitude applications (4R100 continues available for F150 5.4L in California).

Chassis

  • Manual transmission shift lever moved rearward 55 mm, and gets a new rubber boot.
  • Minimum GVWR with 4.2L engine increased 50 lb. to 5600 lb. Minimum GVWR with 4.6L engine increased to 6050 lb.
  • The 95-amp. alternator is canceled. In its place for all gas engines is an alternator with 130-amp capacity; and due to new SAE rating standards will be rated lower: 115-amp. rating in V6 application, and 110-amp. rating in V8 application. Different pulley sizes account for 115/110 difference.
  • New 9.84 inch dual diaphragm brake booster standard with F150 (now same as F250).
  • 4-wheel anti-lock brakes now standard on XLT as well as Lariat. Approximately 12/1/98 (running change) 4-wheel anti-lock brakes will include 4-wheel discs on F150, and 4-wheel anti-lock brakes will become standard on XLT, Lariat and all 5.4L engines (optional on Standard and XL models).
  • Daytime running lights are now available in the U.S. as an LPO Fleet option only.

Wheels and Tires

  • Off-Road Equipment Group RPO includes new LT265/70Rx17C A/T OWL tires on 17x7.5 inch Chromtec wheels, including new hub ornament. P265/70Rx17 A/T OWL and 17-inch Aluminum wheels now included in the new RPO XLT Sport Package (formerly included in the Off-Road Equipment Group).
  • New 16x7 inch 9-hole steel wheel replaces 16x7 inch 18-hole wheel as standard, and is included as the spare wheel with optional 16x7 inch wheels.
  • For 16x7 inch cast aluminum wheel, new 5-spoke design with new hub ornament replaces the 6-spoke.
  • Styled Steel wheels are now standard on all XL trim models. Chrome Styled Steel wheels canceled.

Interior/Exterior

  • New exterior colors, two-tone accent colors, interior and headliner colors.
  • Front-end freshening includes appearance changes to front grille and bumper. Overall dimensions of bumper/valance remains unchanged.
  • Details of other changes are available through the Ford dealers.

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Super Duty F-Series
(Over-8500 lb. GVWR / F250/350/450/550)

Powertrain

  • New "Limited-Function" and "Full-Function" auxiliary idle control kits available for diesel engine, replacing the current Auxiliary Powertrain Control Module (APCM) approximately 11/2/1998. Refer to the General Powertrain section of this book for details.

Chassis

  • Instructions for adjusting the rear ride height of F250/350 4x4 vehicles to accommodate 5th wheel and goose-neck trailers is available in Technical Service Bulletin Article No. 98-17-2.
  • Passenger air bag standard on XL and XLT pickup models (remains optional on Box Delete and Chassis Cab models).
  • Just prior to Job #1, Jan. 1998, the 130-amp alternator rating was revised to 115-amp/1950-watt with gas engines, and 110-amp/1700-watt with diesel engine. The alternator still has 130-amp capacity, but new SAE rating standard was adopted. Different pulley sizes account for the 115/110 difference.
  • Center High Mount Stop Lamp (CHMSL) included standard on single rear wheel models only. CHMSL mounting hole in cabin is covered with plastic insert on dual rear wheel models. The CHMSL is available for volume purchase through Visteon Component Sales Group. Part number is F47B-13A613-AA. A 33 business day lead time is required. The United Group can provide individual parts next-day, at slightly higher cost.
  • New fuel tanks (running change):
    • Chassis Cab 36 gallon aft-of-axle fuel tank increased to 40 gallons (approx. Jan., 1999). Includes a separate frame-mounted skid plate. Description included in MVE Ship-Thru Program Bulletin No. 5, dated June 19, 1998.
    • New 23 gallon auxiliary right hand saddle-mounted diesel fuel tank available on select DRW Chassis Cab models with (in addition to) 19 gallon midship fuel tank and 7.3L V-8 Turbo Diesel engine (approx. Jan., 1999).
  • If unable to use the 90-degree-bend fuel filler pipe-hoses normally included in chassis cab dunnage, a straight fuel filler pipe is available for aft-axle fuel tank by contacting Visteon Component Sales Group, 800-833-4773. The service part number is F81Z-9B149-HA. Volume sales only.

Interior/Exterior

  • Two new exterior colors and new tape stripe.
  • Nomenclature/badging revisions: "XL" added to base trim series fender badges; Triton V-8 and V-10 badges enlarged and new material; new Powerstroke V-8 badges are relocated to the front portion of the door; and "Super Duty" added to F250/350 tailgate badge.
  • Headliner "Chalet" cloth replaced by "Rhonby" cloth.
  • "Alpine" cloth seat material replaced by "Beacon" cloth.
  • Running Changes:
    • Overhead console ave. fuel economy display replaced by outside temperature display.
    • Chrome rear step bumper available with XL trim (requires XL Decor Group).
    • Floor mat in-lieu-of carpet available with Lariat trim.
    • Premium dual media radio available with XL trim.
    • Deluxe polished bright aluminum wheels available with Lariat.
    • Instrument cluster will include speed control set indicator light (12/8/98).

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Econoline Wagon

Powertrain

  • 4R100 automatic transmission replaces E4OD.
  • Fail-safe cooling now a feature on all Econoline gasoline engines, including 4.2L V6.

Chassis

  • Standard on all E350's: 4-wheel disc brakes with 4-wheel ABS (3-channel with Kelsey-Hayes Dynamic Rear Proportioning).
  • Brake dust shields eliminated for all Econoline. Began with vehicles with rear ABS during 1998 calendar year.
  • The shadow band at the top of the windshield was removed from all Econoline as a running change during the 1998 calendar year.
  • Trailer Tow Prep. Package (Class I) and Handling Package are now available on E150 Club Wagon.
  • New Class III trailer tow hitch included as part of the Heavy Duty Trailer Tow Package (90-day running change).

Interior/Exterior

  • Second Generation passenger side air bag.
  • Four new exterior colors and one new interior color.
  • "Midway" floor carpet replaces "Newport" carpet.
  • New exterior vehicle nomenclature badging and Power Stroke diesel engine badge.
  • New Dual Media Radio - Premium AM/FM Stereo, Clock, Cassette, Compact Disc, with six speakers.
  • Revised lower instrument panel bolster section to accommodate new parking brake release lever.
  • Deleted: passenger side power seat with manual lumbar.
  • New full length and door length running boards (running change).

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Econoline Van

Powertrain

  • 4R100 electronic 4-speed automatic transmission replaces E4OD.
  • 4R70W electronic 4-speed automatic transmission standard on all E150/250.
  • New "Limited-Function" and "Full-Function" auxiliary idle control kits available for diesel engine, replacing the current Auxiliary Powertrain Control Module (APCM) approximately 11/2/1998. Refer to the General Powertrain section of this book for details.
  • Fail-safe cooling now a feature on all Econoline gasoline engines, including 4.2L V6.

Chassis

  • Standard on all E350's: 4-wheel disc brakes with 4-wheel ABS (3-channel with Kelsey-Hayes Dynamic Rear Proportioning).
  • Brake dust shields eliminated for all Econoline. Began with vehicles with rear ABS during 1998 calendar year.
  • The shadow band at the top of the windshield was removed from all Econoline as a running change during the 1998 calendar year.
  • P225/75Rx16E All Season OWL Tire added as standard on E250 RV Prep Package.
  • Optional 11,000 lb. GVWR E350 Stripped Chassis available on 158" or 178" wheelbase, with dual rear wheel and 5.4L engine.
  • New Class III Trailer Tow Hitch included as part of the Heavy Duty Trailer Tow Package (90-day running change).

Interior/Exterior

  • Five new exterior colors, and one new interior color.
  • Second Generation passenger side air bag.
  • "Midway" floor carpet replaces "Newport" carpet.
  • New exterior vehicle nomenclature badging and Power Stroke diesel engine badge. All Cutaways will be badged "Super Duty", with E30 and E37 badged "E350 Super Duty', and E40 and E47 badged "E450 Super Duty".
  • New Dual Media Radio - Prem. AM/FM Stereo, Clock, Cassette., CD, with six speakers.
  • Revised lower instrument panel bolster to accommodate new parking brake release lever.
  • Deleted: passenger side power seat with manual lumbar.
  • RV PLUS Package offered for E250 Recreational (incomplete) Vans (E24 only).
  • Dual Cloth Captain's Chairs (21A) offered for Comm. Vans, and Comm. and RV Cutaways.
  • New full length and door length running boards (running change).

"School Bus Body Builder Preparation Package" , Option Code 47S
("Incomplete Vehicle")

  • Available only on E350 Super Duty Commercial Cutaway, 138" wheelbase:
    • SRW / 9,699 lb. GVWR
    • DRW / 10,000 lb. GVWR
  • 47S Package content includes:
    • 7.3L Diesel engine
    • A minimum of 3900 lb. Front Gross Axle Weight Rating (GAWR). The actual front spring will be one spring rating higher than the one normally computer-selected based on the option content ordered without 47S.
    • Driver's door window glass is banded and tinted.
    • Dual electric horn.
    • Right hand seat delete and right hand door delete: High back driver's seat only. Deletes the RH seat belt system, RH seat attaching hardware, RH front scuff plate, RH B-pillar trim, and passenger side air bag. Includes plugs for floor pan seat mounting holes.
    • Requires further manufacture and certification by a final stage manufacturer.

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PTO and High Idle Control
  • New high idle control for 7.3L Turbo Diesel engine in both Super Duty F-Series and Econoline. Two new Auxiliary Powertrain Control Modules (APCM's) released as 1999 model year running change, pproximately December, 1998. The new APCM modules look similar to the old, and also are not weather-proof, nor RFI protected beyond the vehicle driver's cabin. Both modules will be delivered with the vehicle as dunnage.
    • "Limited Function" APCM included in Ambulance Prep Package, and titled in the Order Guide as "Ambulance Auxiliary Idle Control Module - Limited Function". Primary function is battery "charge protection".
    • "Full Function" APCM added as stand-alone option, and titled as "Auxiliary Idle Control
    • Module - Full Function" in the Order Guide. Functions include those in prior year APCM. Additional features include PTO/clutch-pump over-speed protection, clutch engagement
    • speed protection, and ability to control remotely the functions of on/off (through a momentary contact switch), and "vernier-type" rpm control. The "Full Function" APCM
    • can replace APCM units back to 1995 model year usage.
  • Answers to some PTO start-up concerns:
    • "Cannot find the PTO Circuit". The Super Duty F-Series PTO Circuit wiring changed soon after 1/1998 Job #1. The PTO Circuit wires moved more toward the driver's side, under the steering column and onto the harness for the black 4-pin APCM connector. The wires shown as 18-gage are 20-gage. Job #1 began with Circuit 640, red with yellow trace, 18-gage (really 20-gage), then changed to Circuit 295, light blue with pink trace, 20-gage. PTO Circuit 322, correctly remains light blue with yellow trace, but there is another wire with the same color near it (Circuit 323, not related to PTO). To verify that the correct wire is chosen, check to confirm that the 4R100 overdrive-cancel light is illuminated as it normally should be when the PTO Circuit is activated.
    • "Surprised to find that 1200 rpm high-idle is obtained without APCM". To prevent coking of the diesel engine valves, possible with extended low speed idle in extreme cold temperatures, a special strategy was added to the powertrain control module (PCM) of the 7.3L Diesel engine with 4R100-PTO automatic transmission. The strategy automatically raises the engine idle to 1200 rpm when certain environmental conditions are met and the 4R100 is in PARK. The strategy is also signaled when the PTO Circuit is activated and the 4R100 is in PARK.
    • "The PTO Circuit is wired properly but will not respond". When the vehicle battery is disconnected for extended period the powertrain control strategy "forgets" PTO logic and will not respond to commands for elevated idle until it has had a chance to re-count the number of teeth on the gear-set in the 4R100 automatic transmission (36-teeth for non-PTO 4R100 and 115 teeth for the PTO-4R100). To remedy this simply drive the vehicle a short distance. Typically less than a mile will be sufficient to prepare the strategy to respond properly. Driving in first gear will speed this up. Driving stationary with the rear wheels off of the ground will not work. Also note that once the ignition is turned ON, CRANK, and START, sitting and idling for too long before driving may bypass the strategy's "search" cycle, leaving the driving remedy ineffective. If this occurs, shut off the engine and start the cycle over. No need to rush to drive, but avoid unnecessary delay.
  • 6.8L/5.4L/4.6L modular engines may be sensitive to the addition of auxiliary power taken from the crankshaft if the forward crankshaft bearing is not additionally supported. Clutch pumps, air compressors, auxiliary alternators and air compressors are typical applications affected. A minimal load may be acceptable, but not fully researched by Ford. However, excessive cantilever-radial loading of the crankshaft pulley may starve the bearing of proper lubrication and engine failure may result. A bolt-on crankshaft bearing support member is recommended and being developed. Availability from Ford is planned before year-end 1998.

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Trailer Tow Complexity
1999 Super Duty F-Series

Pickups

  • The base Pickup comes with a 4-wire connector at the left rear of the frame.
  • Ordering the "Trailer Towing Package", Option Code 531, provides the following:
    • Seven (7) blunt-cut wires at the left rear of the frame, fully functioning with all relays
    • installed (replacing the 4-wire connector).
    • Front Stabilizer Bar on 4x2. Rear Stabilizer Bar on 4x2 DRW only.
    • Trailer Brake Wiring Kit. Brake controller circuit is labeled and found in the wiring harness
      behind the removable panel under the steering
      column. In-cab brake controller to be purchased separately. Mating connector for under-dash
      trailer brake wire is not available through Ford.
    • HD 78 AH (750 CCA) Battery.
    • HD 115 Amp. Alternator (gas engine only).

Chassis Cab

  • The base Chassis Cab comes standard with seven (7) blunt-cut wires at the left rear of the frame,
    detailed in the chart below. Two of those wires are inoperative because the relays associated with
    them are not included with the chassis, leaving their subsequent purchase and installation an option
    to the customer.
  • Ordering the "Trailer Towing Package", Option Code 531, adds the following:
    • Trailer Brake Wiring Kit. Brake controller circuit is labeled and found in the wiring harness
      behind the removable panel under the steering column. In-cab brake controller to be purchased
      separately. Mating connector for under-dash trailer brake wire is not available through Ford.
    • HD 78 AH (750 CCA) Battery
    • HD 115 Amp. Alternator (gas engine only).

7 Blunt-Cut Wiring Description
Circuit No.: 206  64  52  49  963  962  43
Wire Color: White Dark Green Yellow Orange Black with Light Green Trace Brown with White Trace Dark Blue
Function: Ground Right Turn & Stop lamp Left Turn & Stop Lamp Battery Charge Relay 1/ Backup Lamp Relay 1/ Marker Lamps Brake Controller

1/ For chassis cabs these relays are not included and must be purchased separately.

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Light Truck "Heavy-Duty Emissions" Summary
(This chart does not apply to F800 Medium Truck, or F53 Motor Home Chassis)

1998 Model Year

Engine
GVWR (lb.)
Vehicle Line
Certification
Catalyst
VECI Label Released
(-9C485-)
Federal Calif. 50-State Federal Calif. 50-State
Gas
8501 - 14,000
Econoline
   
yes
 
yes
yes
yes 1/
F-Series 2/
             
Over-14,000
Econoline
   
yes
 
yes
yes
yes 1/
F-Series 2/
             
Diesel 3/, 6/
8501 - 14,000
Econoline
yes
yes
no
yes
yes
yes
no
F-Series 2/
             
Over-14,000
Econoline
no
no 4/
yes
yes
no
no 4/
yes
F-Series 2/
             

 

1999 Model Year

Engine
GVWR (lb.)
Vehicle Line
Certification
Catalyst
VECI Label Released
(-9C485)
Federal Calif. 50-State Federal Calif. 50-State
Gas
8501 - 14,000
Econoline
   
yes
 
yes
yes
yes 1/
F-Series
yes
yes
   
yes
yes
 
Over-14,000
Econoline
   
yes
 
yes
yes
yes 1/
F-Series
   
yes
 
yes
yes
 
Diesel 6/
8501 - 14,000
Econoline
yes
yes
no
yes 5/
yes
yes
no
F-Series
yes
yes
no
yes 5/
yes
yes
no
Over-14,000
Econoline
yes
no 4/
no
yes 5/
yes
no 4/
no
F-Series
yes
yes
yes
yes 5/
yes
yes
yes

NOTES:
1/ LPO-Econoline Cutaway only. Option Code 615 available to Pool Accounts only.
2/ F-Series over-8500 lb. GVWR was not produced for the 1998 model year.
3/ Job #1 1998 MY (August, 1997) diesel products were carry-over 1997 MY.
4/ Job #1 1998 MY (August, 1997) California E-Super Duty was rated for 14,050 lb. GVWR.
    Beginning January 1998, the California E-Super Duty is rated at 14,000 lb. GVWR.
5/ August, 1998 Job #1, 1999 MY diesel products will be carry-over 1998 Econoline, and carry-over January,
  1998 Job #1, 1999 MY F-Series. A change is scheduled for January, 1999 to delete the Catalyst.
6/ Major component changes required to convert diesel from 49-State to California Certification.
   The 1999 F-Series Diesel meets LEV. Econoline Diesel does not.

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Standard, Limited Slip and "Locking" Rear Axle Usage
1999 Super Duty F-Series

NOTE: 4-Wheel ABS (3-channel) is Standard on all DRW Super Duty F-Series, Optional on SRW

Model Option Axle Description Approximate Availability
Size Supplier "Limited Slip" Locking Feature Description Job#1 Jan, 1998 Post Job#1
Trade Name Approx. Bias Ratio (1) Design Type Feature Active
F250 SRW Standard 10.5" Visteon   (none) open differential   X X
Optional Limited Slip   66% / 33% clutch At low speed X X
F350 SRW Standard   (none) open differential   X X
Optional Limited Slip   66% / 33% clutch At low speed X X
F350 DRW

5.4L

Standard   (none) open differential   X X
Optional Limited Slip   66% / 33% clutch At low speed X X
F350 DRW

6.8L, 7.3L

Standard
11.25"
Dana 80
  (none) open differential   X X
Optional Limited Slip Powr-Loc 66% / 33% clutch At low speed X X
F450
Standard   (none) open differential   X X
Optional Limited Slip
No-Slip 50% / 50% full-locking Full-Time Not Avail.

(2)

 
Tru-Trac 58% / 42% torsional Full-Time   11/1998
F550
Standard
14.17"
Dana 135
  (none) open differential   X X
Optional Limited Slip
No-Slip 50% / 50% full-locking Full-Time Not Avail.

(2)

 
Tru-Trac 58% / 42% torsional Full-Time   11/1998


(1) Bias Ratio: The approximate split in torque between opposing rear wheel sets when"limited slip" is active.
(2) The "No-Slip" full-locking axle determined incompatible with corporate standards for 4-wheel ABS performance, and never     made Job#1 production.

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Obtaining Publications

Ford Truck Body Builders Layout Book

Obtain by faxing written request to (734) 414-2971 in U.S. , (905) 670-1798 in Canada. Include the year and model along with your street mailing address (no PO Box). Also note whether you want the book or the CD. The first copy is free.

The September, 1998 printing will include all 1999 model year light trucks. For 1998 and 1999 model year F800, and heavy trucks, refer to the 1997 Ford Truck Body Builders Layout Book. A separate book will be available for Super Duty F650/750 approximately December, 1998.

Incomplete Vehicle Manual

To obtain a generic copy, fax your request to the Ford Truck Body Builders Advisory Service, fax number: (313) 594-2633. Include complete name and mailing address.

If the original IVM that normally comes with the chassis is missing, have your Ford dealer process a "misbuild claim" with the Ford Vehicle Order Processing Center to obtain a replacement.

Ford Recreation Vehicle And Trailer Towing Guide

The guide 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) 245-7343, or faxing to (248) 936-3300.

Service Publications

The "Ford Technical Publications Catalog" lists the service publications available, and includes pricing, an order form, and a mailer. Contact Helm, Inc. on 1-800-782-4356.

Useful publications include "Truck Wiring Diagrams" and the "Service Specifications" book. "Truck Wiring Diagrams" is the new name for "Electrical & Vacuum Trouble Shooting Manual" or (EVTM).

For the "1999 Motor Home Service Service Support Guide Book" contact Ford RV at 800-245-7343, fax: 248-936-3300.

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Important Phone Numbers and Web Sites

INTENDED FOR GENERAL USERS & CUSTOMERS OF COMPLETED VEHICLES

Ford Customer Assistance

Customer Assistance Center: 800-392-3673
Ford Towing Service: 800-241-3673
Web Site: www.ford.com

Ford RV

To locate the nearest RV service center: 800-444-3311
Ford RV & Trailer Tow Guide, and 1999 Motor Home Service Support Guide Book: 800-245-7343; Fax: 248-936-3300

INTENDED FOR FINAL STAGE MANUFACTURERS & VEHICLE MODIFIERS

Ford Truck Body Builders Advisory Services

Light Truck: 877-840-4338; Fax: 313-594-2633
List of Qualified Vehicle Modifiers (ambulance only): 734-455-0059

F-Super Duty Class A Motor Home Chassis Liaison

313-337-6520; Fax: 313-621-8082

Ford Alternative Fuels Information

Vehicle models available, list of authorized Ford dealers, and Leaf & Road Newsletter: 800-ALT-FUEL (800-258-3835)

Ford Aftermarket Support Program

Fax: 313-390-5712

Econoline Aft-of-Axle Fuel Tank Kit (gasoline only)

United Group, Inc.: 800-223-7003

Visteon Component Sales Group

877-682-4276; Fax: 734-666-2167

The United Group, Inc.

800-223-7003 or: 847-816-7100

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