Frame Members
Frame Members
Front Frame Rail
WARNING: Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or damaged vehicles. The use of such parts could lead to serious injury.
Never use non-Ford parts or accessories for completing repairs.
Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain damage which is not visible.
Ford does not approve use of the following:
- Salvaged or used parts
- Major body clips or assemblies from salvage vehicles
- Aftermarket structural or body components
- Salvaged or reconditioned wheels
- Used supplemental restraint system (SRS) components
- air bags
- restraint system modules
- safety belts, buckles or retractors
- crash sensors
Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company engineers.
Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and corrosion protection.
Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative structural component repair procedures and/or parts.
WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.
WARNING: Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.
NOTICE: The following is step-by-step procedure for carrying out front frame horn replacement on Expedition/Navigator models. The Expedition/Navigator is a body on frame vehicle which is designed with energy absorbing features in the front frame horns to manage crash energy. The horn section of the frame MUST NOT be straightened if any holes or surfaces show evidence of collapse or buckling. If any evidence of damage exists BEHIND the first frame crossmember in terms of buckling or cracking, then the ENTIRE frame must be installed new.
NOTICE: Electronic modules and related wiring may be damaged when exposed to heat from welding procedures. Carefully disconnect and remove, or position away from heat affected areas.
NOTE: Prior to beginning this procedure, the vehicle must be restored to its correct overall dimensions. For additional information, refer to Body for dimensional information.
NOTE: The replacement front frame horns are production parts designed with a taper to insert into the mid-rail section to assist in alignment and welding operations. Tow hooks are not included with the replacement frame kit.
NOTE: Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted surfaces or E-coat, or when bare metal repairs are made. For additional information, refer to Restoring Corrosion Protection Following Repair .
NOTE: Observe prescribed welding procedures when carrying out repairs to the frame assembly. For additional information, refer to Welding Precautions - Steel .
1. Position the vehicle on a frame rack following the manufacturer's recommendations. Measure the vehicle to determine body and frame alignment. Refer to Body for dimensional information.
2. Remove the front bumper.
- If equipped, remove tow hooks.
3. Unbolt the Front End Sheet Metal (FESM) and body mount bolts. If necessary, raise the body off the frame assembly.
4. Locate the vertical weld line of the front frame horn to center mid-rail.
5. NOTICE: DO NOT cut directly along the weld line. Leave enough material on the forward side of the weld line to allow the edge to be ground back exactly to the weld line. This is required to assure a correct fit up between the frame and the replacement section.
Using a plasma cutter, reciprocating saw or die-grinder, remove the damaged front frame horn section.
6. NOTICE: Do not thin out the frame rail. The material must maintain a minimum thickness of 3.1 mm (0.12 in) after grinding. This is required to maintain correct energy management in the event of a collision.
Grind off the excess welding material that remains in front of the weld line on the frame mid-rail.
7. Remove the remaining portion of the front frame horn (ring-like piece) from inside the mid-rail with pliers or similar tool.
8. Using a wire brush or sandpaper, remove the E-coat 15 mm (0.59 in) to 20 mm (0.78 in) wide from the inner and outer surfaces of the existing mid-rail. Clean the surfaces with a wire brush and metal surface cleaner.
- Apply a zinc-rich, weld-through primer to the exposed inner and outer mating surfaces.
9. Using a wire brush or sandpaper, remove the E-coat 15 mm (0.59 in) to 20 mm (0.78 in) wide from the inner and outer surfaces of the replacement frame horn section. Clean the surfaces with a wire brush and metal surface cleaner.
- Apply a zinc-rich, weld-through primer to the exposed inner and outer mating surfaces.
10. Install the front section inside the frame mid-rail. Support the replacement frame horn in position. Verify that the FESM mount bracket lines up with the sheet metal hole. The holes should line up so that the FESM mount can be replaced and the FESM mount bolt can be installed.
11. Make sure that the frame and service replacement part have attained a minimum room temperature of 10°C (50°F) before beginning the weld procedure. A Metal Inert Gas (MIG) welder capable of producing 185-250 amps must be used. Use ER70S-3 or ER70S-6 weld wire 0.9-1.1 mm (0.035-0.043 in) diameter that is compatible with SAE 1010 steel. Shielding gas must be 100% carbon dioxide or 75% carbon dioxide and 25% argon.
12. Tack weld the frame horn replacement section into the existing frame at 4 small points centered on the flats between the corners. This will hold the section in place to check the fit up prior to completely welding up the section.
- Measure the frame to make sure factory dimensions are maintained.
13. Make sure the frame section replacement is correctly aligned.
- Carry out the remainder of the welding procedure.
- After welding is complete, grind off any excess weld material.
14. Use a dye penetrant to determine if any cracks or large voids exist in the weld joint after the welding process has been completed.
- If any cracks or other defects exist, grind out the defect and repair it until the imperfection is corrected.
15. Clean the repaired area(s) and any exposed metal surfaces. Restore corrosion protection to the exposed surfaces of the repaired area(s) using anti-corrosion coating on exposed interior and exterior surfaces.
16. Install the components removed during the repair procedure and torque fasteners to the correct specification.