Frame: Service and Repair
Frame Members
Front Frame Rails - Exploded View
WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if damaged. Straighten damaged frame rails to correct frame dimensions prior to frame member sectioning. Failure to follow these instructions may adversely affect frame rail performance and may result in serious personal injury to vehicle occupant(s).
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.
NOTE: Left side shown, right side similar.
WARNING: Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or damaged vehicles. The use of such parts could lead to serious injury.
Never use non-Ford parts or accessories for completing repairs.
Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain damage which is not visible.
Ford does not approve use of the following:
- Salvaged or used parts
- Major body clips or assemblies from salvage vehicles
- Aftermarket structural or body components
- Salvaged or reconditioned wheels
- Used supplemental restraint system (SRS) components
- air bags
- restraint system modules
- safety belts, buckles or retractors
- crash sensors
Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company engineers.
Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and corrosion protection.
Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative structural component repair procedures and/or parts.
1. WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if damaged. Straighten damaged frame rails to correct frame dimensions prior to frame member sectioning. Failure to follow these instructions may adversely affect frame rail performance and may result in serious personal injury to vehicle occupant(s).
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 hood.
3. Remove the battery.
4. Remove the fender(s) from the affected side(s).
5. Remove the front bumper cover.
6. NOTE: If the front bumper beam is not damaged and will be reinstalled, it is spot-welded to the frame rails and must be removed.
Remove the front bumper beam.
7. Remove the upper radiator grille opening panel reinforcement.
8. Discharge the A/C system.
9. Remove the condenser core.
10. Remove the lower radiator support.
11. Scribe a cut-line 230 mm (9.05 in) from the front bumper bracket on the inner frame rail. Using a reciprocating saw, plasma cutter or cut-off wheel, cut completely through the inner and outer frame rails and remove.
12. Scribe a cut-line 60 mm (2.36 in) rearward of the initial frame rail cut, on the outer portion of the rail assembly. Using a cut-off wheel or equivalent, cut and remove that portion of outer rail only. This will create an overlap joint.
13. Measure and cut the inner and outer service replacement rails, equivalent to the length of the damaged frame rail section.
14. Remove the E-coat from the existing frame rails and service replacement rails, including around the holes to be welded, by grinding or sanding until bare metal is visible.
- Wire brush any foreign material from the edges within 15 mm (0.59 in) of the repair joint.
15. Install and clamp the service replacement inner frame rail in place. Tack weld and verify correct alignment of the frame rail.
16. Seam weld along the inside of the section joint using a Metal Inert Gas (MIG) welder and ER70S-3 wire 0.9 mm (0.035 in) to 0.11 mm (0.045 in) diameter wire.
- Verify correct alignment and underbody dimensions.
17. Use a dye penetrant or equivalent to determine if any cracks or large voids exist, grind out any defects that exist and repair until the weld is free of defects.
18. Dress welds as necessary and restore corrosion protection to bare metal surfaces.
19. Install and clamp the service replacement outer frame rail in place.
- Verify correct alignment of the outer frame rail.
20. Seam weld along the section joint of the outer frame rail using a MIG and ER70S-3 wire 0.9 mm (0.035 in) to 0.11 mm (0.045 in) diameter wire.
21. 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.
Using a MIG welder or resistance spot welder, plug weld along the top and bottom seam of the service replacement rails.
22. Use a dye penetrant or equivalent to determine if any cracks or large voids exist, grind out any defects that exist and repair until the weld is free of defects.
- Dress welds as necessary and restore corrosion protection to bare metal surfaces.
23. Reinstall the components removed during disassembly.