2015 FORD E SERIES brakes

GCW (Gross Combined Weight)– is the weight of the loaded vehicle
(GVW) plus the weight of the fully loaded trailer.
GCWR (Gross Combined Weight Rating)– is the maximum allowable
weight of the vehicle and the loaded trailer – including all cargo and
passengers – that the vehicle can handle without risking damage.
(Important: The towing vehicle’s braking system is rated for operation at
GVWR, not at GCWR.) Separate functional brakes should be used for
safe control of towed vehicles and for trailers where the GCW of the
towing vehicle plus the trailer exceed the GVWR of the towing vehicle.
The GCW must never exceed the GCWR.
Maximum Loaded Trailer Weight– is the highest possible weight of a
fully loaded trailer the vehicle can tow. It assumes a vehicle with only
mandatory options, no cargo (internal or external), a tongue load of
10–15% (conventional trailer) or king pin weight of 15–25% (fifth wheel
trailer), and driver only (150 lb. [68 kg]).Consult your authorized
dealer (or theRV and Trailer Towing Guideprovided by your
authorized dealer) for more detailed information.
Tongue Load or Fifth Wheel King Pin Weight– refers to the amount
of the weight that a trailer pushes down on a trailer hitch.
Examples:For a 5,000 lb. (2,268 kg) conventional trailer, multiply 5,000
by 0.10 and 0.15 to obtain a proper tongue load range of 500 to 750 lb.
(227 to 340 kg). For an 11,500 lb. (5,216 kg) fifth wheel trailer, multiply
by 0.15 and 0.25 to obtain a proper king pin load range of 1,725 to
2,875 lb. (782 to 1,304 kg)
WARNING:Do not exceed the GVWR or the GAWR specified on
the Safety Compliance Certification Label.
WARNING:Do not use replacement tires with lower load
carrying capacities than the original tires because they may lower
the vehicle’s GVWR and GAWR limitations. Replacement tires with a
higher limit than the original tires do not increase the GVWR and
GAWR limitations.
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TOWING A TRAILER
WARNING:Do not exceed the GVWR or the GAWR specified on
the certification label.
WARNING:Towing trailers beyond the maximum recommended
gross trailer weight exceeds the limit of your vehicle and could
result in engine damage, transmission damage, structural damage, loss
of vehicle control, vehicle rollover and personal injury.
Note:For information on electrical items such as fuses or relays, see the
Fuseschapter.
The load capacity of your vehicle is designated by weight not volume.
You may not necessarily be able to use all available space when loading
your vehicle or trailer.
Towing a trailer places extra load on the engine, transmission, axle,
brakes, tires, and suspension. Inspect these components before, during
and after towing.
Load Placement
To help minimize how trailer movement affects your vehicle when
driving:
•Load the heaviest items closest to the trailer floor.
•Load the heaviest items centered between the left and right side
trailer tires.
•Load the heaviest items above the trailer axles or just slightly forward
toward the trailer tongue. Do not allow the final trailer tongue weight
to go above or below 10–15% of the loaded trailer weight.
•Select a tow bar with the correct rise or drop. When both the loaded
vehicle and trailer are connected, the trailer frame should be level, or
slightly angled down toward your vehicle, when viewed from the side.
When driving with a trailer or payload, a slight takeoff vibration or
shudder may be present due to the increased payload weight. You can
find more information about proper trailer loading and setting your
vehicle up for towing underLoad limitin theLoad Carryingchapter.
You can also find information in theRV and Trailer Towing Guide
available at your authorized dealer.
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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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