Frame Members-Front Frame Section: Removal

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.

NOTE: The following procedure provides steps to replace the front frame short section at the first frame crossmember.

Restore the vehicle to manufacturer's dimensions. Refer to: BODY DIMENSIONS AND BODY CONSTRUCTION .
Remove the following items:
1. Refer to: Front Bumper - Modular . Refer to: Front Bumper - Plastic .
2. On both sides. Refer to: Wheel and Tire .
3. On both sides. Refer to: Fender .
4. Refer to: Engine Mount LH - 2.3L EcoBoost (199kW/270PS). Refer to: Engine Mount LH - 2.7L EcoBoost (238kW/324PS). Refer to: Engine Mount RH - 2.3L EcoBoost (199kW/270PS). Refer to: Engine Mount RH - 2.7L EcoBoost (238kW/324PS).
5. Refer to: Radiator - 2.3L EcoBoost (199kW/270PS). Refer to: Radiator - 2.7L EcoBoost (238kW/324PS).
6. Unbolt the Front End Sheet Metal (FESM) body mount bolts and raise or remove the body if required. Refer to: Frame and Body Mounting .
Anchor the vehicle to a frame rack following the equipment manufacturer's instructions.
All vehicles

NOTE: This section of the frame

MUST NOT be straightened if any holes or surfaces show evidence of collapse or buckling. If any evidence of damage exists BEHIND the first frame cross member in terms of buckling, cracking, etc. then the entire front frame section or entire frame must be replaced.
NOTE: The replacement front frame components are production parts designed with a taper to insert into the front rail section to assist in alignment and welding operations.

Front frame short section overview.

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NOTE: This section of the frame MUST NOT be straightened if any holes or surfaces show evidence of collapse or buckling. If any evidence of damage exists BEHIND the first frame cross member in terms of buckling, cracking, etc. then the entire front frame section or entire frame must be replaced.

NOTE: Do not cut directly along the center of the weld line. Leave 10mm material on the front side of the weld centerline to allow the remaining weld and frame material to be ground back to the front edge of the front mid rail. This is necessary to make sure of correct fit between the frame and the replacement frame section.

NOTE: RH side shown in illustration, LH side similar.

Locate the vertical weld of the front frame to center rail, using a plasma cutter, reciprocating saw or cut-off wheel cut through the frame rail.
- Using a chisel gun with a sharp 25.4 mm (1 inch) wide wedge chisel, separate the ground area of the joints.
  Use the General Equipment: Grinder
  
  Use the General Equipment: Plasma Cutter
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Remove the frame section from the affected side.

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Grind off the excess welding material that remains around the perimeter of the front edge of the front frame rail of the frame assembly, and remove the remaining portion of the frame section from inside the frame rail. Use the General Equipment: Locking Pliers

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Usingawirebrushorsandpaper,removetheecoatpaintfromtheexistingframeneartheedgestobe weldedontheinnerandoutersurfaceswithinapproximately15mm(0.5in.)oftherepairjoint.

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All vehicles

NOTE: The front frame section on this vehicle is retained by welded lap joints. The frame section will be removed and installed by grinding of the original welded joints, followed by welding of the new section into position.
Front frame section overview.

Courtesy of FORD MOTOR COMPANY
Remove the following items:
1. Refer to: Transmission Support Crossmember - 2.3L EcoBoost (199kW/270PS) . Refer to: Transmission Support Crossmember - 2.7L EcoBoost (238kW/324PS) .
2. If equipped. Refer to: Front Driveshaft .
3. If equipped. Refer to: Halfshaft .
4. Refer to: Shock Absorber and Spring Assembly .
5. Refer to: Front Stabilizer Bar .
6. Raise and support the engine and transmission assembly. Refer to: Engine Mount LH - 2.3L EcoBoost (199kW/270PS). Refer to: Engine Mount LH - 2.7L EcoBoost (238kW/324PS). Refer to: Engine Mount RH - 2.3L EcoBoost (199kW/270PS). Refer to: Engine Mount RH - 2.7L EcoBoost (238kW/324PS).
7. Remove the lower control arm. Refer to: Lower Arm .
8. Remove the upper control arm. Refer to: Upper Arm .
9. Refer to: Steering Gear .
10. Disconnect the exhaust system for the engine. Refer to: Catalytic Converter - 10-Speed Automatic Transmission - 10R60 - 2.3L EcoBoost (199kW/270PS). Refer to: Catalytic Converter - 7-Speed Manual Transmission - MT88 - 2.3L EcoBoost (199kW/270PS). Refer to: Catalytic Converter LH - 2.7L EcoBoost (238kW/324PS). Refer to: Catalytic Converter RH - 2.7L EcoBoost (238kW/324PS).
Loosen the body mount to frame bushing bolts from the radiator support and the forward cab support.
Disconnect and remove any remaining wiring, lines, and related fittings from the frame section.
Grind through the original welded joints retaining the forward frame section to the center section. Be careful not to cut into the center side rail since it will be reused.
- Using a chisel gun with a sharp 25.4 mm (1 inch) wide wedge chisel, separate the ground area of the joints. Use the General Equipment: Grinder
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With the help of an assistant, remove the complete front frame section.

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Using a wire brush or sandpaper, remove the e-coat paint from the existing frame near the edges to be welded on the inner and outer surfaces within approximately 15 mm (0.5 in.) of the repair joint.

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