Frame Members — Front

Special Tool(s)

	Rust Inhibitor Installation Kit 286-00002
	Undercoating Spray Gun 286-00001

Front Frame Rail

 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: Right side shown, left side similar.

NOTE: Cut line shown in illustration is approximate, refer to the following procedure for specific cut locations.

 WARNING: Collision damage repair must conform to the instructions contained in this workshop manual. 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 in this manual, 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.

 WARNING: 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.

 WARNING: Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.

NOTICE: This sectioning procedure is only recommended when collision damage does not extend into the front shock tower area. For more severe collision damage, repairs must be made at the original factory seam and joint locations. Failure to follow these instructions may compromise the structural integrity of the vehicle.

NOTE: The following repair procedure illustrates the sectioning of the front side member and fender reinforcement components. In situations where collision damage is less severe, the sectioning procedure to repair only those damaged components may be determined from these procedures.

1. Position the vehicle on a frame repair rack following the manufacturer's recommendations. Measure the vehicle to determine if the body requires straightening and alignment. For additional information, refer to Body in this section for dimensional information.
   • Remove the front bumper. For additional information, refer to Section 501-19 .

2. Remove the engine. For additional information, refer to Section 303-00 .

3. Remove the suspension components. For additional information, refer to Section 204-01 .

4. NOTICE: The frame rail sectioning instruction kit provides the specific service procedure instructions for replacement of the frame rail sectioning kit. It is mandatory that the replacement section be installed per the installation guidelines. The frame rail service component must be located to maintain the original factory dimensions. For additional information, refer to Body in this section for correct underbody dimensional information.

   Remove the radiator support assembly.

5. Cut off the front apron from the main part of the apron, 80.5 mm (3.16 in) forward of the 14 mm (0.55 in) x 20 mm (0.78 in) slot, and remove the remainder of the apron.

6. NOTE: Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas (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.

   NOTE: Refer to welding equipment manufacturer's instructions for correct machine set up.

   Drill out the spot welds in the front fender apron reinforcement.

7. Drill out the spot welds attaching the shock tower to the apron panel, and the apron to the lower rail.
   • Dress all spot weld surfaces.

8. Chamfer inner and outer side member cutline surfaces to improve butt weld surfaces.

9. Measure 12.5 mm (0.49 in) rearward from the lower rail cutline. Drill seven 8 mm (0.31 in) holes in the insert overlap area flange.

10. Transcribe the inner front side member cutline to the new lower side member, cut to length and chamfer the butt end to improve the weld surface.

11. Construct an insert from the unused inner side member material.

12. Measure 12.5 mm (0.49 in) forward from the lower rail cutline. Drill nine 8 mm (0.31 in) holes in the new lower side member for attachment of the insert.

13. Apply corrosion protection to the repair areas on the vehicle and service parts.

14. Position the insert to the new lower side member, clamp and check fit and alignment. MIG plug weld 9 holes.

15. Measure underbody to verify correct dimensions. For additional information, refer to Body in this section for dimensional information.

16. Position the new radiator support assembly, apron panel, rail assembly, front fender lower reinforcement and front fender upper reinforcement.
    • MIG plug weld all holes.

17. Fusion weld the front fender upper and lower reinforcements to the front fender apron, front fender apron to the radiator support and the seam between the old and the new side members.
    • Dress all welds.

18. Install the engine. For additional information, refer to Section 303-00 .

19. Install the suspension components. For additional information, refer to Section 204-01 .