Frame #4 Crossmember - Crack or Weld Separation
Article No.94-20-2
10/05/94
^ FRAME - # 4 CROSSMEMBER - GUSSET CRACKS OR WELD SEPARATION
^ NOISE - "RATTLE" FROM THE REAR OF THE VEHICLE
FORD:
1990-92 CROWN VICTORIA
LINCOLN-MERCURY:
1990-92 GRAND MARQUIS, TOWN CAR
ISSUE:
A "rattle" noise may come from the rear of the vehicle. This occurs because the frame's # 4 crossmember gussets crack or there are weld separations from the frame rails.
ACTION:
Inspect the # 4 crossmember gussets for cracks or weld separations from the frame rails and, if necessary, install new gussets. Refer to the following procedure for service details.
1. Raise the vehicle on a hoist and place jackstands under the rear axle. Refer to the appropriate Lincoln Town Car, Crown Victoria/Grand Marquis Service Manual, Section 00-02.
2. Disconnect rear stabilizer bar from gussets. Refer to the Service Manual, Section 04-02, for removal procedure. Refer to Figure 1.
3. Lower exhaust system from rear of vehicle. Refer to the Service Manual, Section 09-00.
4. Remove fuel tank from the vehicle. Refer to the Service Manual, Section 10-01, for removal procedure.
WARNING:
FUEL TANK MUST BE REMOVED FROM VEHICLE BEFORE WELDING.
5. Remove lower arm (5538/9), pivot bolt and nut from axle bracket only. Refer to the Service Manual, Section 04-02.
6. Saw/chisel off old gussets flush with the # 4 crossmember.
7. Grind off old weld and any paint on mating surfaces.
8. Position the new gussets (FOAZ-5D020-B, RH and FOAZ-5D021-B, LH) and weld gussets to frame side rail first, then weld to # 4 crossmember. Refer to Figure 2.
a. Use "MIG" gas-shielded arc welding or "STICK" weld process.
b. Refer to the Lincoln Town Car, Crown Victoria/Grand Marquis Service Manual, Section 01-00, for welding precautions.
9. Repaint welded area with black paint (Sherwin Williams # 1234567 or equivalent meeting Ford specification ESA-M62J16-A).
10. Reassemble all components.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992 Models, Basic Warranty Coverage For 1990-91 Models
OPERATION DESCRIPTION TIME
942002A Remove And Replace # 4 3.3 Hrs.
Crossmember Gussets
DEALER CODING
BASIC PART NO. CONDITION CODE
5DO20 01
OASIS CODES: 304000, 305000, 702000, 702200