Frame Members - Rear
Frame Members - Rear
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.
- 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: Because of component composition (Dual Phase Steel (DP) 600 steel) a frame rail sectioning kit is not available for this vehicle. Frame rail replacement must be carried out by replacement at the factory seams.
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 rear bumper cover and reinforcement.
3. Remove the rear wheels.
4. Remove the rear axle.
5. LH side only. Remove the fuel fill assembly.
6. NOTE:
- Use caution not to drill through the vehicle floor pan when removing spot welds.
- LH side shown. RH side similar.
Carefully remove the spot welds and the rear frame rail.
Installation
1. Dress all spot weld nuggets on the vehicle mating surfaces.
2. 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.
Drill plug weld holes in the replacement rear frame rail service part.
3. Apply a locally available weld-through primer to the immediate weld location only on the replacement part and vehicle mating surfaces.
4. Install and clamp the service replacement rear frame rail in place and verify correct alignment of the frame rail.
5. Using a MIG welder or resistance spot welder, plug weld the service replacement rail.
6. Apply corrosion protection. For additional information, refer to Restoring Corrosion Protection Following Repair.
7. Install a new rear bumper mounting plate.
8. LH side only. Install the fuel fill assembly.
9. Install the rear axle.
10. Install the rear wheels.
11. Install the rear bumper cover and reinforcement.