TL113025 E350-450 Cutaway Manual AF Rotary Switch design 2

10nov16jh

TL113025 INSTALLATION MANUAL

FOR TELMA AF50-55 ON FORD E-350/450 CUTAWAY with rotary foot switch design 2

including MY2016 changes

TL113025

Ford E-350/450 Cutaway Installation Manual with AF50-55 and rotary switch design 2

Page 2 of 40__________________________________________________________________________10nov16jh

TABLE OF CONTENTS 1 Preparation of the Chassis

1.1 Driveline 1.2 Exhaust

2 Telma Installation 2.1 Installation Kit TIK10689 2.2 Install the Chassis Brackets 2.3 Assemble the Telma Brackets and mounts 2.4 Install the Telma in the Chassis 2.5 Drive Shaft Modification and Installation 2.6 Axle Shim Installation

3 Control Components 3.1 Relay Box Installation 3.2 Light Bar Installation 3.3 TRCM Installation 3.4 Rotary Foot Switch Installation

4 Wiring Harness Installation 4.1 Power Harness Installation 4.2 Control Harness Installation 4.3 Wiring Diagram

5 Recommended Tools 6 Post Install Checklist 7 Appendix

7.1 E350 138” WB with 5.4L engine & 5R110 transmission (X1=-2) 7.1.1 E350 138” WB with 6.8L engine & 5R110 transmission (X1=-2) 7.1.2 E350 138” WB with 6.8L engine & 6R140 transmission (X1=-2) 7.2 E350/450 158” WB with 5.4L engine & 5R110 transmission (X1=6) 7.2.1 E350/450 158” WB with 6.8L engine & 5R110 transmission (X1=6) 7.2.2 E350/450 158” WB with 6.8L engine & 6R140 transmission (X1=6) 7.3 E450 176” WB with 6.8L engine & 5R110 transmission (X1=24) 7.3.1 E450 176” WB with 6.8L engine & 6R140 transmission (X1=24) 7.3.2 E450 158to176” WB with 6.8L engine & 5R110 transmission (X1=6) 7.3.3 E450 158to176” WB with 6.8L engine & 6R140 transmission (X1=6) 7.4 E450 176to186” WB with 6.8L engine & 5R110 transmission (X1=24) 7.4.1 E450 176to186” WB with 6.8L engine & 6R140 transmission (X1=24) 7.4.2 E450 158to186” WB with 6.8L engine & 5R110 transmission (X1=6) 7.4.3 E450 158to186” WB with 6.8L engine & 6R140 transmission (X1=6) 7.5 E450 176to190” WB with 6.8L engine & 5R110 transmission (X1=24) 7.5.1 E450 176to190” WB with 6.8L engine & 6R140 transmission (X1=24) 7.5.2 E450 158to190” WB with 6.8L engine & 5R110 transmission (X1=6) 7.5.3 E450 158to190” WB with 6.8L engine & 6R140 transmission (X1=6) 7.6 E450 176to208” WB with 6.8L engine & 5R110 transmission (X1=24) 7.6.1 E450 176to208” WB with 6.8L engine & 6R140 transmission (X1=24) 7.6.2 E450 158to208” WB with 6.8L engine & 5R110 transmission (X1=6) 7.6.3 E450 158to208” WB with 6.8L engine & 6R140 transmission (X1=6)

TL113025


Page 3 of 40__________________________________________________________________________10nov16jh

SECTION 1 PREPARATION OF THE CHASSIS 1.1 DRIVELINE

Remove the complete drive-line assembly from the transmission flange yoke to the rear axle flange yoke.

1.2 EXHAUST

Due to transmission angle changes by FORD for model year 2016 chassis and 6R140 six speed transmission it was necessary to move the Telma to the passemger side by ½”. This change now requires an exhaust modification on these chassis. E350 138” wheelbase may still require a shorter muffler. 2016 CHASSIS EXHAUST MODIFICATION

TL113025


Page 4 of 40__________________________________________________________________________10nov16jh

SECTION 2 RETARDER INSTALLATION

2.1 INSTALLATION KIT TIK10689

P/N DESCRIPTION QTY JZ1007XX-45 Telma Shock Mount Set - 45 Shore 1LFA101156 AF50-55 / 12v with 156 index 1TIB01017 CONTROL/RELAY BOX BRACKET 2TIB01041 Rotary Foot Switch Bracket 1TIB01037 TRCM Bracket E450 1TIB07000e Chevy / Ford AF50-55 Chassis Bracket 2TIB07011 AF50-55 Passenger Side Plate Bracket 1TIB07012 AF50-55 Driver Side Plate Bracket 1TID17002 OBD2 HARNESS WITH JD331121 for rotary foot switch design 2 1TIF01064 hex head bolt 1/4 - 28 x 1.25 grade 8 yellow zinc for TRCM mounting 2TIF01066 nylon insert locknut 1/4-28UNF for pedal clamp and TRCM mounting 4TIF01067 M4-0.7 x 20mm DIN 933 Class 8.8 Zinc Cap Screw for rotary switch mounting 1TIF01068 M4 DIN 137 Zinc Wave Washer for rotary switch mounting 1TIF05005 BOLT 1/4-28UNF x 3/4 HEX HEAD G8 for TRCM bracket pedal clamp mounting 2TIF05010 LOCKWASHER 5/16 SPLIT 4TIF05011 NUT 5/16-18UNC 4TIF05012 BOLT 5/16-18UNC x 1-1/2 HEX HEAD G5 4TIF05013 BOLT 1/2-13UNC x 1-1/2 HEX HEAD G5 2TIF05014 LOCKWASHER 1/2 MED SPLIT 2TIF05034 Fender Washer - 1/4 x 1OD zinc plated 1TIF07000 12pt Head Bolt M12 x 1.75 x 30 flange yoke bolts 8TIF07001 M12X1.75X35 10.9 HEX HEAD BOLT for retarder bracket 6TIF07002 7/16-14 x 1.75 Hex Flange Bolt Grade 8 for chassis bracket 12TIF07003 7/16-14 Hex Flanged Locknut Grade 8 for chassis bracket 12TIG11010 TELMA LIGHT BAR DISPLAY 1TIG31063 Telma Control Module Ford E450 CAN 1TIG31066 rotary foot switch 1VF201400 Trep washer M12 for retarder bracket 6

TL113025


Page 5 of 40__________________________________________________________________________10nov16jh

2.2 INSTALL THE CHASSIS BRACKETS Remove any bolts such as battery box and/or exhaust hanger mounts that will interfere with the chassis bracket

mounting Mark the reference hole T1 from the top of the frame down to the reference hole. Mark the reference hole CC from the center of the transmission u-joint or X1 from the body mount hole. Drill a single 7/16” hole in the frame and bolt the chassis bracket (TIB07000) against the outside of the frame using

the reference hole in the center of the bracket and 4.25” down from the top of the bracket. Rotate the bracket to the angle specified on the installation drawing.

NOTE: Use electronic anglemeter with 0.1° accuracy (e.g. SPI Pro360 digital protractor). All angles indicated are with frame reference of 0°.

Drill four additional 7/16” holes in each frame rail using the chassis bracket as a template and secure chassis bracket to frame with the flanged head bolts 7/16-14UNC x 1.75" (TIF07002) and flanged lock nuts (TIF07003) included in the kit.

Tighten the 7/16” bolts to 70 lb-ft (±10%). Drill through the chassis bracket any holes needed for battery box and/or exhaust hanger mounts and reinstall the

original bolts that were previously removed. It may be necessary to make a 5/16” spacer to keep the accessory brackets flush on the outside of the frame rail.

Brackets are slotted so that they can be installed in the stretch area.

TL113025


Page 6 of 40__________________________________________________________________________10nov16jh

2.3 ASSEMBLE THE TELMA BRACKETS AND MOUNTS Identify the driver’s side of the Telma from the passenger side. The power connection block is on the passenger

side top corner and the ground is on the driver side top corner. Identify the Telma brackets. The longer bracket TIB07012 is for the driver’s side. The shorter passenger side

bracket is TIB07011. Use medium strength thread locking adhesive (e.g. Loctite 243) on all fasteners and mark with paint after

tightening to proper torque. Use three hex head bolts M12x1.75x35mm (TIF07001) equipped with yellow thread locking patch and Trep washers

(VF201400) provided in the kit to attach each Telma bracket onto the unit. Tighten bolts to 35 lb.-ft. (±5 lb-ft) CAUTION: DO NOT OVERTIGHTEN!

Install the rubber mounts into the retarder brackets as shown below. Insert the male parts of the rubber mounts into the 1 5/8” holes in the brackets from the bottom and the other half of the rubber mount on top. Place one 2 ¾” diameter 5/8” flat washer on the top and bottom of each mount and another on the bottom between the chassis bracket and nut.

2.4 INSTALL THE TELMA IN THE CHASSIS Lower the Telma, equipped with its brackets and mounts, into place on top of the chassis brackets. Install the M16x1.5x100mm (4”) bolts and spring washers down through the holes in the mounts and brackets at

each mount. Install 2 ¾” diameter flat washers, spring washers and M16 locknuts at each mount as shown below and tighten to 150 lb.-ft (±10%).

TL113025


Page 7 of 40__________________________________________________________________________10nov16jh

2.6 DRIVE SHAFT MODIFICATION and INSTALLATION A slip assembly is required on each side of the Telma. Slip position should be at center of slip travel when shaft is

installed Refer to FORD QVM guidelines and SPICER recommendations for proper drive shaft manufacture, balance,

straightness, and critical speed limits. Refer to the appendix for Telma guidelines Use u-joint SPICER part number SPL36-1X (1410) Refer to installation drawings in the appendix for shaft length guidelines and minimum tube diameter requirements. Always verify proper shaft lengths before modification Connect the Telma flange yoke of each drive shaft to the Telma coupling flange using the M12x1.75x25mm 12 point

head bolts (TIF07000) equipped with yellow thread locking patch supplied in the kit. Tighten to 80 lb-ft (±10%). Mark with paint after tightening to proper torque.

TL113025


Page 8 of 40__________________________________________________________________________10nov16jh

TL113025


Page 9 of 40__________________________________________________________________________10nov16jh

2.7 AXLE SHIM INSTALLATION

TL113025


Page 10 of 40__________________________________________________________________________10nov16jh

SECTION 3 CONTROL SYSTEM COMPONENTS INSTALLATION 3.1 RELAY BOX MOUNTING Install the relay box on the inside driver side frame rail using an existing hole approximately 40” forward from the

center of the Telma and down 1 1/2“ from the top of the frame rail using the relay box mounting brackets TIB01017 x 2 and fasteners supplied in the kit.

Tighten the four 5/16” bolts to 17 lb-ft (±10%) and the two ½” bolts to 75 lb-ft (±10%).

3.2 LIGHT BAR INSTALLATION The Light Bar should be mounted so that it is easily visible to the driver. Make a rectangular hole 7/8” wide x 1 ¾” tall in the lower dash to the right of the steering column or install the Light

Bar in an existing console receptacle. Install the mating connector onto the five wires (org/wht, blu/wht, yel/grn, brn/wht, blk) found in the relay box control

harness. Feed the harness through the hole and connect to the Light Bar Plug the light bar into the hole

LIGHT BAR DISPLAY

PANEL

TL113025


Page 11 of 40__________________________________________________________________________10nov16jh

3.3 TELMA CONTROL MODULE INSTALLATION Bracket TIB01037 is used to mount the Telma Control Module to the dash as shown below. Use the two ¼” x 1.25” long bolts (TIF01064) to attach the TRCM to the bracket and the two ¼” x 0.75” long bolts (TIF05005) along with fender washer TIF05034 to attach the bracket under the dash as shown below. Use four nylon insert lock nuts TIF01066 supplied in the kit. Tighten to 12 lb-ft ±10%.

TL113025


Page 12 of 40__________________________________________________________________________10nov16jh

3.4 ROTARY FOOT SWITCH INSTALLATION Install the rotary switch TIG31066 on the bracket TIB01041 as shown below using the M4x0.7x20mm bolt (TIF01067) and washer (TIF01068) supplied in the kit. Tighten to 12 lb-in ±10%. Install the rotary foot switch bracket TIB01041 to the lower right pedal cluster mounting stud as shown below.

TL113025


Page 13 of 40__________________________________________________________________________10nov16jh

SECTION 4 WIRING HARNESS INSTALLATION 4.1 ELECTRICAL HARNESS COMPONENTS

Control ModuleTelma PN: Date Code:

TL113025


Page 14 of 40__________________________________________________________________________10nov16jh

4.2 POWER HARNESS INSTALLATION From the relay box, route the Telma power connection and ground harness along the inside of the left frame rail

and up over the top along the middle of the Telma. Connect the 10G orange, blue, yellow, and brown wires to the connecting block at the top right corner. Connect the 10G relay box ground cable and the 4G Telma main ground cable to the insulated ground terminal at the Telma top left corner. Coat the terminals with anti-corrosion paint or body undercoat after the connections are made. Secure the harness to the center of the Telma brackets with rubber coated cable clamps. The harness should be secured along the centerline of the Telma and as far away as possible from either rotor to avoid heat damage to the harness. No cables should cross the heat outlets in the periphery of the rotors. Continue across with the black 4G ground cable and connect to negative terminal of the battery pack on the passenger side. Route the red power positive cable along the cross member in front of the Telma and connect to the positive terminal of the battery pack on the passenger side. Secure the cable to the cross member with rubber coated cable clamps.

POWER CONNECTIONS AT

TOP RIGHT CORNER

GROUND CONNECTION AT

TOP LEFT CORNER

SECURE HARNESS TO RETARDER

TL113025


Page 15 of 40__________________________________________________________________________10nov16jh

4.3 CONTROL HARNESS INSTALLATION Open the driver’s door and remove the plastic foot well insert and the rubber plug towards the rear in the bottom of

the body. From the relay box, feed the control cable along the inside of the frame rail, up through the hole in the cab where the plug was removed. Continue feeding the harness from the foot well area behind the left kick panel and up under the dash towards the steering column area. Make sure the harness does not interfere with the parking brake mechanism and cannot be damaged when the parking brake is actuated.

Find the Telma Control Module cab harness and insert the two plugs into the module. Plug the foot switch connector onto the rotary foot switch. Remove the OEM OBD2 diagnostics connector from its attachment points under the dash and plug the mating

OBD2 connector of the Telma harness into the OEM OBD2 connector. Secure together with a wire tie. Attach the OBD2 connector of the Telma harness to the OEM attaching points where the OEM OBD2 diagnostics connector was installed.

Attach the mating connector to the four wires (org, blu, yel, brn) found in the relay box control harness and plug into the cab harness receptacle labeled “to relay box”.

After installation is complete, connect the PC to check TRCM configuration and test the system as an end-line-line quality check. Set speed to 0 mph temporarily to test the system when stopped to ensure proper function. Do not forget to change speed cutoff back to 1.0 mph after testing. In particular, check “transducer” voltage output in the diagnostics page to make sure voltage is less than Stage 1 set point when the brake pedal is not applied to avoid stage 1 activation without brake application. Adjust brackets or change set points if necessary. It may be necessary to unplug the gray connector from the module and reconnect in order to power cycle after a configuration change has been made. The configuration settings for Ford Econoline are in the table below. Make sure to check telmausa.com for the latest Telma Desktop Client to use and the firmware revision required for your application.

Configuration Settings Ford E-Series with rotary foot switch Low/High Low CAN Ford E&F Speed 1.0mph Set point Stage 1 0.5 Set point Stage 2 1.0 Set point Stage 3 1.5 Set point Stage 4 2.0

TL113025


Page 16 of 40__________________________________________________________________________10nov16jh

4.4 WIRING DIAGRAM

SECTION 5 RECOMMENDED TOOLS

Transmission Jack Heavy duty drill motor Standard assortment of mechanics hand tools Vehicle hoist, pit, or floor jack with stands Electrical connector crimping pliers for use with non-insulated connectors Electronic angle meter with 0.1° accuracy (e.g. SPI Pro360 digital protractor) Laptop or desktop Windows computer with DB9 serial port or USB-to-serial port adapter

TIG01027. Straight through DB9 serial cable (male/female)

TL113025


Page 17 of 40__________________________________________________________________________10nov16jh

SECTION 6 POST INSTALL CHECKLIST TL133010 Revised 19may15 INSTALLATION FOLLOWUP CHECKLIST

CHASSIS #:

CHASSIS MAKE/MODEL: Telma part number: Telma Serial number: End Customer: Retain a copy of this checklist in the chassis VIN record INSTALLER: Record Telma serial number in electronic VIN record INSPECTION DATE:

INSPECTED BY:

√ X COMMENTS

ELE

CT

RIC

AL

harness properly routed along center of Telma away from rotors and secured with cable clamps to retarder bracket

minimum 1/4" clearance between chassis bracket and retarder bracket

harnesses routed on inside of frame rail away from heat sources, sharp edges, etc. and secured with rubber coated metal cable clamps

correct cable eyelet size at battery / disconnect switch

relay box mounted vertical with wiring exiting from the bottom and can be easily accessed

Telma battery power cable connected to battery switch or to battery "+" terminal and is protected with corrosion inhibitor

Telma battery ground cable connected to frame rail bare metal surface where battery pack is grounded or directly to battery ground post and protected with corrosion inhibitor

relay box ground connected to retarder ground post electrical connections (weatherproof connectors, no quick splice, avoid butt connectors)

Light Bar Display installed correctly, visible to driver, and operates properly

Telma Control Module accessible and secured with screws Telma foot control shuts off automatically at 1mph Telma activates when moving and brakes are applied Connect PC to TRCM to check proper configuration and function

ME

CH

AN

ICA

L

Telma hydraulic brake foot switch brackets installed correctly cables, hoses and air lines are at least 4" from rotors or heat shield installed

drive shaft weld quality, slip installed on each side of Telma at center of travel, balance, u-joints same quality as OEM

Transmission angle measurement

Telma angle measurement

First shaft angle and installed length measurement

Second shaft angle and installed length measurement

Third shaft angle and installed length measurement

Fourth shaft angle and installed length measurement

Axle angle measurement

drive shaft lengths/angles, Telma angle conforms to drawing Flange yokes are in same plane

TL113025


Page 18 of 40__________________________________________________________________________10nov16jh

APPENDIX

TL113025


Page 19 of 40__________________________________________________________________________10nov16jh

VEHICLE TECHNICAL DATACHASSIS MAKE / MODEL FORD E350 CONTROL MODULE TRCMWHEELBASE 138.0" TIRE SIZE 225/75R-16ENGINE MAKE / MODEL FORD 5.4L GVW / GCW 11500 lbsTRANSMISSION MAKE / MODEL FORD 5R110 AXLE RATIO 4.10AXLE MAKE / MODEL DANA 70 DRIVE LINE SERIES 1410 SPL36DRIVE TYPE 4 X 2 Use OEM U-JOINT SPL36-1XRETARDER MODEL AF50-55 FLANGE YOKE 3-2-429RETARDER PART NUMBER LFA101156 SUSPENSION Spring/Mor-RydeTELMA attests that this drawing corresponds to industry standards concerning driveline angularities and critical speedsThis drawing is valid for the application specified only. Always check all angles and dimensions for your installation.Consult TELMA technical department if your application varies in any way

Dc loaded: 10Dv unloaded: 10 3/4

Dv chassis only: 12 1/4

L2 CHASSIS ONLY (±1.0°)= 10.0° AXLE CHASSIS= 4.5°

TRANSMISSION= 4.5° CHASSIS BRACKET= -0.8° L2 UNLOADED WITH BODY (±1.0°)= 6.9° AXLE UNLOADED= 4.5°L1= 6.3° RETARDER= 4.5° L2 LOADED (±1.0°) = 5.4° AXLE LOADED= 4.5°

A B1 C1 R1 T1 X1 L1 L23 3/4 6 3/8 7 3/8 13 1/16 4 -2 SHAFT LENGTH 23 7/8 27 7/8S1 S2 S4 SR CC SHAFT MINIMUM TUBE DIAMETER 2.50 2.50

18 1/4 23 3/4 23 1/2 23 3/4 30 1/4 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths. angle tolerance=±0.2°NOTE 2: All drive shafts must be dynamically balanced after modification. dimension tolerance=±1/16"NOTE 3: Always verify proper shaft lengths before modificationNOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaftNOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned.

NOTE 6: Install chassis bracket against inside bottom lip of frame railNOTE 7: After installation is completed, measure drive shaft angles and compare to the angles on the installation drawing.

Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawingNOTE 8: USE BRACKETS TIB07000e, TIB07011, TIB07012NOTE 9: Check axle angle after body is installed and if necessary adjust to 4.5° with frame reference of 0°

TL113025


Page 20 of 40__________________________________________________________________________10nov16jh





TRANSMISSION= 4.5° CHASSIS BRACKET= -0.8° L2 UNLOADED WITH BODY (±1.0°)= 7.4° AXLE UNLOADED= 4.5°L1= 5.8° RETARDER= 4.5° L2 LOADED (±1.0°) = 5.9° AXLE LOADED= 4.5°

A B1 C1 R1 T1 X1 L1 L24 6 1/8 7 1/8 13 1/16 3 3/4 -2 SHAFT LENGTH 20 7/8 27 7/8S1 S2 S4 SR CC SHAFT MINIMUM TUBE DIAMETER 2.50 2.50




TL113025


Page 21 of 40__________________________________________________________________________10nov16jh





TRANSMISSION= 5.5° CHASSIS BRACKET= 0.0° L2 UNLOADED WITH BODY (±1.0°)= 6.2° AXLE UNLOADED= 5.3°L1= 6.9° RETARDER= 5.3° L2 LOADED (±1.0°) = 4.7° AXLE LOADED= 5.3°

A B1 C1 R1 T1 X1 L1 L24 6 4/8 7 6/8 13 1/16 4 1/4 -2 SHAFT LENGTH 20 7/8 27 7/8S1 S2 S4 SR CC SHAFT MINIMUM TUBE DIAMETER 2.50 2.50




TL113025


Page 22 of 40__________________________________________________________________________10nov16jh

VEHICLE TECHNICAL DATACHASSIS MAKE / MODEL FORD E350/E450 CONTROL MODULE TRCM

WHEELBASE 158.0" TIRE SIZE 225/75R-16

ENGINE MAKE / MODEL FORD 5.4L GVW / GCW 14500 lbs

TRANSMISSION MAKE / MODEL FORD 5R110 AXLE RATIO 4.56

AXLE MAKE / MODEL DANA 70HD DRIVE LINE SERIES SPL36

DRIVE TYPE 4 X 2 Use OEM U-JOINT SPL36-1X

RETARDER MODEL AF50-55 FLANGE YOKE 3-2-429

RETARDER PART NUMBER LFA101156 SUSPENSION Spring / Mor-Ryde

TELMA attests that this drawing corresponds to industry standards concerning driveline angularities and critical speedsThis drawing is valid for the application specified only. Always check all angles and dimensions for your installation.Consult TELMA technical department if your application varies in any way

Dc loaded: 10

Dv unloaded: 10 3/4


L2 CHASSIS ONLY (±1.0°)= 7.3° AXLE CHASSIS= 4.5°TRANSMISSION= 4.1° CHASSIS BRACKET= -0.8° L2 UNLOADED WITH BODY (±1.0°) = 4.9° AXLE UNLOADED= 4.5°

L1= 3.9° RETARDER= 4.5° L2 LOADED (±1.0°) = 3.7° AXLE LOADED= 4.5°

A B1 C1 R1 T1 X1 L1 L23 3/4 6 3/5 7 5/8 13 1/16 4 1/4 6 SHAFT LENGTH (±0.25") 41 3/4 36 1/4

S1 S2 S4 SR CC SHAFT MINIMUM TUBE DIAMETER 3.00 3.0018 1/4 23 3/4 23 1/2 23 3/4 48 1/8 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083

NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths.NOTE 2: All drive shafts must be dynamically balanced after modification. general dimension tolerance (except shaft lengths)= ±1/16"NOTE 3: Always verify proper shaft lengths before modification general angle tolerance (except L2) = ±0.2°NOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaftNOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned.



TL113025


Page 23 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4




A B1 C1 R1 T1 X1 L1 L24 6 5/8 7 5/8 13 1/16 4 1/4 6 SHAFT LENGTH (±0.25") 38 3/4 36 1/4





TL113025


Page 24 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4


L2 CHASSIS ONLY (±1.0°)= 7.2° AXLE CHASSIS= 4.5°TRANSMISSION= 5.5° CHASSIS BRACKET= 0.0° L2 UNLOADED WITH BODY (±1.0°) = 4.8° AXLE UNLOADED= 5.3°


A B1 C1 R1 T1 X1 L1 L24 6 1/2 7 3/4 13 1/16 4 1/4 6 SHAFT LENGTH (±0.25") 38 13/16 36 1/8S1 S2 S4 SR CC SHAFT MINIMUM TUBE DIAMETER 3.00 3.00

18 1/4 23 3/4 23 1/2 23 3/4 45 1/4 SHAFT MINIMUM TUBE THICKNESS 0.083 0.083NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths.NOTE 2: All drive shafts must be dynamically balanced after modification. general dimension tolerance (except shaft lengths)= ±1/16"NOTE 3: Always verify proper shaft lengths before modification general angle tolerance (except L2) = ±0.2°NOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaftNOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned.



TL113025


Page 25 of 40__________________________________________________________________________10nov16jh

VEHICLE TECHNICAL DATACHASSIS MAKE / MODEL FORD E450 CONTROL MODULE TRCM









Dc loaded: 10

Dv unloaded: 10 3/4









TL113025


Page 26 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4




A B1 C1 R1 T1 X1 L1 L24 6 48/49 7 3/4 13 1/16 4 1/2 24 SHAFT LENGTH (±0.25") 38 3/4 54




Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawingNOTE 8: USE BRACKETS TIB07000e, TIB07011, TIB07012NOTE 9: Adjust axle angle after body is installed to 3.3° with frame reference of 0°

TL113025


Page 27 of 40__________________________________________________________________________10nov16jh


WHEELBASE 176.0" stretch from 158 TIRE SIZE 225/75R-16








Dc loaded: 10

Dv unloaded: 10 3/4









TL113025


Page 28 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4









TL113025


Page 29 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4









TL113025


Page 30 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4








Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawingNOTE 8: USE BRACKETS TIB07000e, TIB07011, TIB07012NOTE 9: Check axle angle after body is installed and adjust to 3.3° with frame reference of 0°

TL113025


Page 31 of 40__________________________________________________________________________10nov16jh





AXLE MAKE / MODEL DANA 70 DRIVE LINE SERIES 1410 SPL36





Dc loaded: 10

Dv unloaded: 10 3/4


TRANSMISSION= 4.1° L3 CHASSIS ONLY (±1.0°) = 6.1° AXLE CHASSIS ONLY= 2.5°

L1= 3.7° CHASSIS BRACKET= -2.8° L3 UNLOADED WITH BODY (±1.0°) = 3.7° AXLE UNLOADED= 2.5°


A B1 C1 P R1 T1 X1 L1 L2 L3

4 7 7/8 8 3/8 5 13/16 13 1/16 5 1/4 6 SHAFT LENGTH 28 38 7/8 36 1/8

S1 S2 S4 S6 SR CC SHAFT MIN TUBE DIA 3.00 3.00 3.00

18 1/4 23 3/4 23 1/2 23 1/4 23 1/4 73 1/4 SHAFT MIN TUBE THICKNESS 0.083 0.083 0.083

NOTE 1: Drive shaft lengths are measured from center of U-joint and are installed lengths. angle tolerance=±0.2°

NOTE 2: All drive shafts must be dynamically balanced after modification. dimension tolerance=±1/16"

NOTE 3: Always verify proper shaft lengths before modificationNOTE 4: When not specified, the front & the rear drive shafts, on each retarder side, must have at least the same slip as the original drive shaft

NOTE 5: When not specified, the flange yoke on each retarder side must have the maximum working angle capacity available in the driveline series concerned.

NOTE 6: USE BRACKETS TIB07000e, TIB07011, TIB07012NOTE 7: After installation is completed, measure drive shaft angles and compare to the angles on the installation drawing.

Contact TELMA Customer Support Engineering if the angles measured do not conform to the drawing

NOTE 8: Clamp the chassis bracket against the inside of the frame rail at dimension X1 from the body mount holeand dimension T1 from the outside top of the frame.

NOTE 9: Adjust carrier bearing so that second u-joint offset (S6) is 23.25"

NOTE 10: Adjust carrier bearing so that second shaft (L2) angle is 4.1° with frame reference of 0°

NOTE 11: Adjust axle angle after body is installed to 2.5° with frame reference of 0°

TL113025


Page 32 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4





A B1 C1 P R1 T1 X1 L1 L2 L3

4 7 3/4 8 4/8 6 13 1/16 5 1/4 6 SHAFT LENGTH 28 38 7/8 36 1/8










NOTE 9: Adjust carrier bearing so that second u-joint offset is the same as the transmission


TL113025


Page 33 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4




A B1 C1 R1 T1 X1 L1 L24 7 7 3/4 13 1/16 4 1/2 24 SHAFT LENGTH (±0.25") 52 3/4 54 1/4





TL113025


Page 34 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4









TL113025


Page 35 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4





A B1 C1 P R1 T1 X1 L1 L2 L3

4 8 8 3/4 6 13 1/16 5 1/2 6 SHAFT LENGTH 32 38 7/8 36 1/8











NOTE 10: Check axle angle after body is installed and adjust to 2.5° with frame reference of 0°

TL113025


Page 36 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4





A B1 C1 P R1 T1 X1 L1 L2 L3

4 8 8 3/4 6 1/4 13 1/16 5 1/2 6 SHAFT LENGTH 32 38 7/8 36 1/8











NOTE 10: Check axle angle after body is installed and adjust to 3.3° with frame reference of 0°

TL113025


Page 37 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4





A B1 C1 P R1 T1 X1 L1 L2 L3

4 7 7/8 8 3/8 5 15/16 13 1/16 5 1/4 24 SHAFT LENGTH 32 38 7/8 54 1/8













TL113025


Page 38 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4





A B1 C1 P R1 T1 X1 L1 L2 L3

4 7 13/16 8 4/8 6 3/16 13 1/16 5 1/4 24 SHAFT LENGTH 32 38 7/8 54 1/8












TL113025


Page 39 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4





A B1 C1 P R1 T1 X1 L1 L2 L3

4 7 7/8 8 3/8 6 9/16 13 1/16 5 1/4 6 SHAFT LENGTH 50 38 13/16 36 1/8












NOTE 11: Check axle angle after body is installed and if necessary adjust to 2.5° with frame reference of 0°

TL113025


Page 40 of 40__________________________________________________________________________10nov16jh










Dc loaded: 10

Dv unloaded: 10 3/4





A B1 C1 P R1 T1 X1 L1 L2 L3

4 8 1/8 8 5/8 6 6/16 13 1/16 5 8/16 6 SHAFT LENGTH 37 51 7/8 36 1/8












Documents

TL113025 E350-450 Cutaway Manual AF Rotary Switch design 2