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This paper discusses the techniques employed in the development of the 1975 Ford Econoline Van, Club Wagon, and Cutaway vehicles. The presentation highlights the key elements of engineering a new family of light trucks. A brief review of historical van and bus market trends and their role in determining new vehicle design objectives is included. Specific engineering subjects discussed are: ˙Body-on-frame structural design applied to van/bus/cutaway vehicles. ˙Development of an energy absorbing frame for these forward control trucks. ˙Engineering techniques applied to the resolution of vehicle shake problems. ˙Modifications to front and rear suspension for optimum ride, handling and tire wear. ˙Development of integrated climate control systems for van/bus vehicles. ˙The engineering of derivatives for body builder recreation vehicle markets.

The purpose of this paper is to discuss handling in the context of those operational variables and vehicle chassis considerations which are most significant in affecting the handling properties of light trucks. In discussing handling for normal driving the Cornering Compliance Concept is used to combine the most significant parameters in a simple lumped parameter model. Limit handling performance and the mechanics of rollover are discussed in the paper. It is observed that exposure to limit handling maneuvers is unlikely to occur in normal driving. The significance of vehicle handling properties to highway safety is an unknown at this time.