Suspension - Spring Tower Flange Cracking
TSB 05-22-1611/14/05
SPRING TOWER WELD REPAIR AND REPLACEMENT PROCEDURE
FORD:
1997-2006 E-350, E-450
This article supersedes TSB 05-1-1 to update the vehicle model years and service procedure.
ISSUE
Some higher-mileage E-350 and E-450 cutaway vans may exhibit cracks in the left or right spring tower flange.
ACTION
Certain front spring tower cracks can be repaired effectively by welding a reinforcement plate at the crack following the Service Procedure in this TSB. If the crack does not meet the criteria for this reinforcement plate repair, the spring tower should be replaced.
SPRING TOWER CRACK REPAIR PROCEDURE
NOTE
SPRING TOWER CRACK REPAIR USING THE REINFORCEMENT PLATE WELD PROCEDURE SHOULD ONLY BE PERFORMED IF THE FOLLOWING CONDITIONS ARE MET.
^ The crack must exist in a location that is accessible and allows proper repair. Use the reinforcement plate procedure to repair areas where a welded reinforcement plate can be installed while maintaining adequate clearance to the spring and other components
^ The crack must have no branches. Flange edges shall be separated or misaligned by no more than 1/8" (3 mm)
^ LH front spring tower cracks must be no longer than 1.5" (38 mm)
^ RH front spring tower cracks must be no longer than 1.25" (32 mm)
If any of the above conditions are not met, see the Spring Tower Replacement procedure at the end of this bulletin.
EQUIPMENT REQUIRED
^ MIG welding equipment is required and should be capable of 150 amps or greater using ER70-6 welding wire
^ A straight or right angle die grinder is effective for repair preparation
REINFORCEMENT PLATE REPAIR MATERIAL SPECIFICATION
^ Reinforcement plates used in this repair procedure can be made from low carbon steel of the correct grade and thickness, similar to the front spring tower. They should be roughly rectangular shape. Other shapes may be cut and used for improved fit to the affected area of the flange, or to provide improved reinforcement. Repairs to non-flat areas of the spring tower flange require reinforcement plates to be formed to fit the contour of the spring tower. In some cases, the service spring tower part may be suitable as a source for the reinforcement plate
^ The spring tower is made of low carbon steel (SAE J403, grade 1008-1010). Spring tower material thickness is approximately 0.19" (4.8 mm)
^ Reinforcement plate material thickness should be in the range of 0.18"- 0.23" (4.6-5.8 mm) Approximate reinforcement plate size should be 4" +/- 3/8" long, by 5/8" +/- 1/8" wide (102 +/- 10 mm long, by 16 mm +/- 3 mm wide)
^ Reinforcement plates should be uncoated, free of rust or oil, and have smooth edges and surfaces
REPAIR PROCEDURE
NOTE
A REINFORCEMENT PLATE IS REQUIRED TO REPAIR EACH CRACK.
1. Disconnect the battery. Use precautions to protect vehicle and customer installed equipment from damage during welding.
2. Support the vehicle on a frame hoist.
3. Remove the front wheel assembly on the side to be repaired.
4. Loosen the front shock absorber at upper attachment, or disconnect the front shock at the lower attachment, to permit the axle to move down so the spring can be removed. Remove the front spring upper retainer and the front spring. Refer to the E-Series Workshop Manual. If required for inspection or repair access, also remove the shock from vehicle.
5. Cover the wheel end, brake rotor and brake hoses with a welding blanket to protect from grinding debris and weld spatter.
6. Clean or de-grease spring tower and ensure that all cracks have been identified. Prepare suitably sized reinforcement plates for the repair.
7. LH only, if necessary for access, remove the rear most steering gear bolt and apply tape over the hole to protect it from weld spatter.
8. Remove frame wax or E-coat from the spring tower in the areas to be welded, with a straight or right angle die grinder with a Scotch-Brite(TM) (or similar pad) and wax and grease remover. Include areas of the flange where the reinforcement plate will be welded to the spring tower. Also, clean up the back or inboard side of the flange in the area to be repaired.
9. Use a small burr tool to grind along the crack and form a U-groove for weld metal deposit. The U-groove should extend from the trimmed flange to approximately 3/8" (10 mm) beyond the visible end of the crack. No more than 1 mm of the original metal thickness should remain in the ground area at the "bottom" of the U-groove.
10. Use a 36 grit 3" grinding disk and chamfer any sharp edges along the U-groove, and grind the spring tower flange edge smooth 1" (25 mm) on either side of the crack location.
11. Using a MIG welder, fill the crack from its termination back toward the initiation point at the trim edge of the spring tower flange.
12. Cool the repair weld with an air blast and inspect.
13. Grind the weld flush with the original outboard surface of the spring tower. The recommended grinding direction for this operation is perpendicular to the direction of crack.
14. Check the reinforcement plate for proper fit-up to the repaired area.
15. If access to the flange edge is good, position and clamp the reinforcement plate on the spring tower flange so that the plate's edge is flush with the flange edge (butt joint edge).
NOTE
IF ACCESS TO THE FLANGE EDGE IS POOR, POSITION AND CLAMP THE REINFORCEMENT PLATE ON THE SPRING TOWER FLANGE SO THAT THE PLATE'S EDGE IS SLIGHTLY INSIDE THE FLANGE EDGE (LAP JOINT EDGE).
16. Begin by tack welding the reinforcement plate in place starting at the plate's edges farthest from the crack. Check MIG welder torch access for the weld pass, then make a weld along the inside edge of the reinforcement plate. Vertical down weld direction is preferred when possible.
17. Recheck for proper fit-up, adjust as required, and then make another weld pass along the outside edge of the reinforcement plate. A vertical down weld direction is preferred when possible.
18. Cool the welded area with an air blast and inspect. If required, grind smooth to remove excess weld material and/or stress concentrations.
19. Apply corrosion inhibiting paint, Motorcraft Low Temperature Anti-Corrosion Coating (PM-12-A), to the repair area.
20. Reassemble the vehicle and secure fasteners to the proper torques, as specified in the Workshop Manual.
NOTE
VERIFY THE "T" SHAPED END OF THE UPPER SPRING RETAINER IS PROPERLY ENGAGED AND SEATED IN THE SLOT AT THE TOP OF THE SPRING TOWER BEFORE THE FASTENER IS SECURED.
NOTE
LH SIDE ONLY - IF STEERING GEAR BOLT WAS REMOVED, REAPPLY THREAD ADHESIVE TO THE BOLT BEFORE IT IS INSTALLED AND TORQUED.
SPRING TOWER REPLACEMENT
Spring Towers can be replaced if the above conditions for Spring Tower Repair are not met. These parts are for installation by a skilled welder at an appropriate vehicle repair facility according to the general frame welding guidelines in Section 502 of the E-Series Workshop Manual.
Refer to TSB 97-4-7 for replacement of the Spring Tower to #1 cross member rivet with a bolt.
NOTE
IF THE HOLES AND MOUNTING FEATURES ON THE RIGHT HAND SIDE (RHS) SERVICE PART ONLY DO NOT LINE UP WITH THOSE ON THE ORIGINAL EQUIPMENT COMPONENTS, AND THE VEHICLE WAS BUILT FROM 1/19/2001 THROUGH 4/10/2001, THEN THE REPLACEMENT BOLT HOLE SHOULD BE DRILLED AS OUTLINED IN FIGURE 1. RHS SPRING TOWERS FOR VEHICLES BUILT PRIOR TO 1/19/2001 WILL REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE. RHS SPRING TOWERS FOR VEHICLES BUILT AFTER 4/10/2001 SHOULD NOT REQUIRE DRILLING FOR THE RHS REPLACEMENT BOLT HOLE.
Parts Block
WARRANTY STATUS: Information Only - Not Warrantable
OASIS CODES: 304000 305000
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