Part 2

Removal and Installation

Front Frame Section:

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.

- 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.
- 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: Regular cab 4x2 with 8-foot pickup box, Heavy Duty trailer tow option does not have rear frame section service kit available and cannot be sectioned. Failure to follow these instructions may affect collision energy management of the vehicle.

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.
- Observe prescribed welding procedures when carrying out repairs to the frame assembly. For additional information, refer to Welding Precautions - Steel.

1. Remove the rear bumper assembly.
2. Remove the rear tailgate assembly and complete pickup box assembly.
3. Lower and remove the spare tire and remove the spare tire carrier assembly from the frame section.
4. If equipped, remove the frame dampener located on the left rear frame rail.







5. Drain and remove the fuel tank assembly. Plug the open lines.
- Disconnect and remove the evaporative emissions unit from the frame section.

6. Remove exhaust hangers and the exhaust system.
7. Position the vehicle on a frame rack and anchor in place following the manufacturer's guidelines.

8. NOTE: All body alignment measurements are carried out with the vehicle detrimmed. Measurements are made metal-to-metal, on center unless otherwise specified.

Measure the vehicle to determine if the body and frame requires straightening and alignment. For body dimensional information, refer to Specifications / Dimensions.

9. Position and tighten fixtures to hold the front eye bolts of the leaf spring attachments. This will secure the rear axle and spring assembly in place as the frame section is removed and replaced.

10. Using the frame rack towers, position a support chain under the rear cab mount area of the center section of the frame and apply light tension to secure the cab and center section in place.
11. Remove the rear shock absorbers.

12. WARNING: Adjust the rear axle height to relieve spring tension before removing any shackle bolts, nuts or spring pins. Springs under tension may release with great force. Failure to follow this instruction may result in serious personal injury.

Remove the rear spring eye bolts. With the help of an assistant, hold the spring down with a large pry bar, then slowly release tension after removing the bolt.

13. NOTE: The rear frame section on this vehicle is retained by a welded joint near the forward leaf spring eye brackets.

Using a high-speed grinder and correct eye, face and ear protection, grind through the original welded joints retaining the forward spring eye brackets to the frame rail and remove the brackets completely.

14. Using a plasma cutter, reciprocating saw or cut-off wheel, remove the damaged front frame horn section. Do not cut directly along the weld line. Leave enough material on the front side of the weld line to allow the edge to be ground back exactly to the line. This is necessary to make sure of correct fit between the frame and the replacement frame section.
15. Grind off the excess welding material that remains in front of the weld line on the existing frame.
- Remove only the weld material. Do not grind out the center frame rail that must be reused.

16. Using an air chisel with a sharp one inch wedge-type chisel, separate the ground area of the joints.
17. With the help of an assistant, remove the complete rear frame section.







18. With the help of an assistant, position the replacement section into the center section of the frame.
- Loosely clamp the replacement section in place.

19. Carry out frame measurements to verify correct position of the replacement section and clamp firmly into position. For body dimensional information, refer to Specifications / Dimensions.
20. Make sure the repair joint and surrounding repair area have attained a minimum temperature of 10°C (50°F) before carrying out weld procedure.
21. Weld the joint completely, if fit and alignment are correct, using a metal inert gas (MIG) welding machine capable of producing a minimum of 200 amps. Use 0.9-0.11 mm (0.35-0.045 in) ER70S-3 or equivalent weld wire that is compatible with SAE 1010 steel.
22. Dress weld(s) as necessary.
23. Use a dye penetrant to determine if any cracks or large voids exist in the weld joint. If cracks or other defects exist, grind out the defect and repair until the weld is free of defects.
- Clean the repair area with metal surface cleaner and apply anti-corrosion coating to the affected areas of the frame and service replacement section.

24. Install the front axle brackets and verify correct position.
- Tack weld into position and carry out a final measurement.

25. Weld the joint completely, if fit and alignment are correct, using a metal inert gas (MIG) welding machine capable of producing a minimum of 200 amps. Use 0.9-0.11 mm (0.35-0.045 in) ER70S-3 or equivalent weld wire that is compatible with SAE 1010 steel.
26. Use a dye penetrant to determine if any cracks or large voids exist in the weld joint. If cracks or other defects exist, grind out the defect and repair until the weld is free of defects.
- Clean the repair area with metal surface cleaner and apply anti-corrosion coating to the affected areas of the frame and brackets.

27. Reinstall the spare tire carrier assembly.
28. Reinstall the fuel tank and evaporative emissions unit.
29. Reinstall the exhaust system.
30. Reinstall the rear springs, shocks and components removed during disassembly.
31. If equipped, reinstall the frame dampener on the frame rail of service replacement frame.
- Tighten to 47 Nm (35 lb-ft).







32. Reinstall the pickup box assembly.
33. Remove the vehicle from the frame rack and complete any final assembly required.