Frame Members
Frame Members
Front Frame Rail(s)
NOTE: Instruction sheet included with service replacement components.
Frame Compatibility Bracket � 4WD Pickup Single Rear Wheel (SRW) only
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.
WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if damaged. Straighten damaged frame rails to correct frame dimensions prior to frame member sectioning. Failure to follow these instructions may adversely affect frame rail performance and may result in serious personal injury to vehicle occupant(s).
NOTICE: The front frame rail kit is the only serviceable component of the frame assembly. Follow the manufacturer's prescribed procedure included with the service replacement kit to avoid compromising collision energy management.
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. Remove the front bumper assembly.
2. Remove the grille assembly and reinforcement.
3. Remove the front fenders.
4. Remove the front skid plate (if equipped).
5. NOTE: Brackets and fasteners are serviced separately from the frame kit and can be reused if undamaged.
Remove the frame compatibility brackets (if equipped).
- To install, tighten to 90 Nm (66 lb-ft).
6. Remove the engine mount retaining bolts and loosen the exhaust manifold-to-head pipe connections.
7. Loosen the radiator shroud retainer bolts.
8. Position the vehicle on a frame rack following the manufacturer's recommendations.
9. Remove the front wheels.
10. Measure the vehicle to determine body and frame alignment. For additional information, refer to Body for dimensional information.
11. Carry out complete removal of the front suspension and steering components including upper and lower control arms, steering gear and steering linkage, sway bar springs and shocks.
12. If equipped, remove front drive axle assembly.
13. Raise and support the engine and transmission assembly and remove the transmission support crossmember.
14. Loosen the body mount-to-frame bushing bolts from the radiator support and the forward cab support.
15. Using the frame rack towers and light tension, support the front radiator support of the vehicle by raising it slightly above the frame rail mounts.
16. Disconnect and remove any remaining wiring, lines and related fittings from the frame section.
NOTICE: The front frame section is retained by rivets and welded lap joints, along with welded joints on the reinforcement gusset for each side. It is critical to a correct repair that correct safety, welding and measurement procedures be adhered to during this procedure.
17. Locate and scribe cut lines on the original front frame section as shown.
- Support the front frame section with stands.
18. Using a reciprocating saw, cut-off wheel or plasma cutter, cut along the scribe lines.
- Remove the damaged section with the help of an assistant.
19. Grind off the remaining gusset from the top and bottom of the side rails.
NOTICE: Do not thin out the frame rail. The material must maintain a minimum thickness of 6.7 mm (0.26 in) for all pickups, 7.1 mm (0.27 in) for all F-350 chassis cabs, and 8.1 mm (0.31 in) for all F-450/550 chassis cabs after grinding or structural integrity can be affected.
20. Grind off the excess front rail material that remains inside of the rear rail. Open up the boxed section for grinding and rivet removal.
21. Drill a 4 mm (0.15 in) pilot hole through each rivet.
22. Drill an 8 mm (0.31 in) hole through the shank of each rivet.
- Remove the rivet heads with an air chisel.
23. Drive out the rivets with a punch.
24. Sand off as much of the frame coating as possible using 36 to 60 grit sandpaper on the inner and outer surfaces within a minimum of 20 mm (0.78 in) of the repair joint, including the overlap.
25. Use a wire brush to remove any foreign material from the frame within 25 mm (0.98 in) of the repair joint inside and out, and clean the bare metal with metal surface prep.
26. NOTE: The replacement section is supplied with the crossmember reinforcement gussets tack welded to the section. The gussets are removed, then rewelded in the following steps.
Cut and grind off the tack weld(s) from the crossmember gussets (from the service replacement section) on both sides and remove the gussets.
27. With the help of an assistant, position the service replacement frame section into place on the vehicle.
- Support and clamp the section in place and verify the correct alignment and frame dimensions of the replacement section.
28. Ream the rivet holes to 14 mm (0.55 in) and install the 10 M14 bolts, washers and nuts.
- Tighten to 189 Nm (139 lb-ft).
29. Carry out a final measurement of the replacement frame section. Verify the forward cab mounting surface position relative to the center cab mounting surface, as shown above. This will verify the cab fits the new frame.
30. Tack weld the new fasteners.
31. 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 0.9 mm (0.035 in) - 1.1 mm (0.043 in) ER70S-3 or equivalent weld wire that is compatible with SAE 1010 steel. Shielding gas must be 100% carbon dioxide, or 75% carbon dioxide and 25% argon.
32. Weld the LH front rail to the rear rail.
- 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.
33. Weld the RH front rail to the rear rail.
- 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.
34. Install and weld the crossmember gussets into position.
35. Weld the top of No. 1 crossmember reinforcement as shown.
36. Weld the bottom of No. 1 crossmember reinforcement as shown.
37. Restore corrosion protection to all bare metal surfaces and allow to dry a minimum of 15 minutes.
- Apply a quality spray undercoating on top of the anti-corrosion coating.
38. Verify the suspension, steering, braking and driveline components are not damaged and reinstall.
39. Remove the vehicle from the frame rack and carry out the remaining reassembly procedures required.