Frame Members-Front Frame Section: Installation

Front Frame Short Section 

1. Verify dimensional accuracy before performing any welding operations. Refer to: Body And Frame .
2. Sealer or adhesive must be applied with a minimum height of 6 mm. Refer to: Sealer, Underbody Protection Material And Adhesives
3. 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.
   NOTE: Check that the Front End Sheet Metal (FESM) body mount bracket lines up with the sheet metal hole for the body mount bolt.

   Install the front frame section inside the mid front rail of the frame and tack weld at 4 locations. Refer to: Joining Techniques

   Use the General Equipment: MIG/MAG Welding Equipment Use the General Equipment: Locking Pliers

   Courtesy of FORD MOTOR COMPANY

4. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joint completely if this alignment is correct. Use the General Equipment: MIG/MAG Welding Equipment

   Courtesy of FORD MOTOR COMPANY

5. Metal finish the repair area using typical metal finishing techniques.
6. Refinish using a Ford approved paint system.
7. Restore corrosion protection. Refer to: Corrosion Prevention
8. Sealing work: All areas must be sealed to production level. Refer to: Sealer, Underbody Protection Material And Adhesives

   Front Frame Section 

9. With the help of an assistant, position the new front frame section into place on the vehicle.

   Courtesy of FORD MOTOR COMPANY

10. Verify dimensional accuracy before  performing any welding operations. Refer to: Body And Frame .
11. Support the new section, and loosely clamp the replacement section in a preliminary position.
    • Verify correct dimensions, then solid weld the new section to the original on all overlap joints. Refer to: Body And Frame Refer to: Joining Techniques

      Use the General Equipment: MIG/MAG Welding Equipment Use the General Equipment: Locking Pliers

    Courtesy of FORD MOTOR COMPANY

12. NOTE: SuperCrew only, LH side shown, RH side similar.

    If equipped, install the barrier tubes.

    Torque: 66 lb.ft (90 Nm)

    Courtesy of FORD MOTOR COMPANY

13. Metal finish the repair area using typical metal finishing techniques.
14. Refinish using a Ford approved paint system.
15. Restore corrosion protection. Refer to: Corrosion Prevention
16. Install the following items:
    1. Refer to: Transmission Support Crossmember .
    2. If equipped. Refer to: Front Driveshaft .
    3. If equipped. Refer to: Front Halfshaft LH . Refer to: Front Halfshaft RH .
    4. Refer to: Shock Absorber and Spring Assembly - RWD . Refer to: Shock Absorber and Spring Assembly - 4WD .
    5. Refer to: Front Stabilizer Bar - 4WD . Refer to: Front Stabilizer Bar - RWD .
    6. Lower the engine and transmission assembly. Refer to: Engine Mount LH . Refer to: Engine Mount RH .
    7. Refer to: Lower Arm - RWD . Refer to: Lower Arm - 4WD .
    8. Refer to: Upper Arm - RWD . Refer to: Upper Arm - 4WD .
    9. Refer to: Steering Gear - RWD . Refer to: Steering Gear - 4WD .
    10. Connect the exhaust system to the engine. Refer to: Catalytic Converter .
    11. Install the body-frame mounting bushes. Refer to: Frame and Body Mounting .

    All vehicles 

17. Install the following items:
    1. Refer to: Radiator .
    2. Refer to: Front Bumper .
    3. Refer to: Fender .