Frame Members - Front

Frame Members - Front












Front Structure

NOTE: Right side fender reinforcements and apron shown, left side similar.







WARNING:
- Frame rail crush zones absorb crash energy during a collision and must be replaced if damaged. Prior to replacement of frame rail crush zones, straighten damaged frame rails to correct frame dimensions. Failure to follow these instructions may adversely affect frame rail crush zone performance and may result in serious personal injury to vehicle occupants in a crash.
- 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.
- Collision damage repair must conform to the instructions contained. Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are not authorized by Ford.
- Departure from the instructions provided, including alternate repair methods or the use of substitute components, risks compromising crash safety. Failure to follow these instructions may adversely affect structural integrity and crash safety performance, which could result in serious personal injury to vehicle occupants in a crash.
- Frame rail crush zones absorb crash energy during a collision and must be replaced if damaged. Prior to replacement of frame rail crush zones, straighten damaged frame rails to correct frame dimensions. Failure to follow these instructions may adversely affect frame rail crush zone performance and may result in serious personal injury to vehicle occupants in a crash.
- 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.

NOTICE: A frame rail sectioning kit is not available for this vehicle. Frame rail replacement must be done at the factory seams. Failure to follow this direction will result in an incorrect repair and vehicle energy management will be compromised.

1. Position the vehicle on a frame repair rack following the manufacturer's recommendations. Measure the vehicle to determine if the body requires rough straightening and alignment. For dimensional information, refer to Body.
2. Remove the hood.
3. Remove the fender(s) from the affected side(s).
4. Remove the front bumper cover and reinforcement.
5. Remove the battery.
6. Remove the front strut from the affected side of the vehicle.
7. Remove the engine mount from the affected side of the vehicle.
8. Remove the subframe.
9. Disconnect and position aside the Anti-Lock Brake System (ABS) sensor wire.

10. NOTE: Use care not to drill through to fender apron or A-pillar when removing the frame rail.

Carefully drill out the spot welds and remove the outer frame rail.







11. NOTE: Use care not to drill through to fender apron or A-pillar when removing the frame rail.

Carefully drill out the spot welds and remove the inner frame rail.







12. Dress any plug weld nuggets on the vehicle underbody structure resulting from inner or outer rail removal.

Installation

1. NOTE: Factory spot welds may be substituted with either resistance spot welds or MIG plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.

Apply a locally available weld-through primer only to the immediate weld locations of the inner and outer frame rails.

2. Install and clamp the service replacement inner frame rail in place. Tack weld and verify correct alignment of the frame rail.

3. NOTE: Factory spot welds may be substituted with either resistance spot welds or MIG plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.

Install and clamp the service replacement outer frame rail in place.
- Verify correct alignment of the outer frame rail.

4. Using a MIG welder or resistance spot welder, plug weld along the top and bottom seam of the service replacement rails.
5. Use a dye penetrant or equivalent to determine if any cracks or large voids exist, grind out any defects that exist and repair until the weld is free of defects.
- Dress welds as necessary.

6. Apply corrosion protection. For additional information, refer to Restoring Corrosion Protection Following Repair.
7. MIG plug weld or resistance spot weld a new front bumper reinforcement mounting plate to the front frame rail assembly.
8. Install the subframe.
9. Install the engine mount from the affected side of the vehicle.
10. Install the front strut.
11. Connect the Anti-Lock Brake System (ABS) sensor wire.
12. Install the battery.
13. Install the fender(s).
14. Install the front bumper cover and reinforcement.
15. Install the hood.