Frame Members-Front Frame Section: Installation

Front Frame Short Section 

1. Verify dimensional accuracy before performing any welding operations. Refer to: BODY DIMENSIONS .
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

   (501-25 Body Repairs - General Information, General Procedures).Use the General Equipment: MIG/MAG Welding EquipmentUse 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. Install the SORB bracket replacement assembly in position and tack weld at 4 locations. Refer to: JOINING TECHNIQUES

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

   Courtesy of FORD MOTOR COMPANY

6. 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

7. Install the SORB gusset bracket replacement assembly in position and tack weld at 2 locations at the top. Refer to: JOINING TECHNIQUES

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

   Courtesy of FORD MOTOR COMPANY

8. Hold the SORB gusset bracket replacement assembly in same position and tack weld at 2 locations at the bottom. Refer to: JOINING TECHNIQUES

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

   Courtesy of FORD MOTOR COMPANY

9. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joints completely if the alignment is correct.
   1. Weld length - 50mmUse the General Equipment: MIG/MAG Welding Equipment
   2. Weld length - 68mm
   3. Weld around inside perimeter, minimise start/stop.

   Courtesy of FORD MOTOR COMPANY

10. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joints completely if the alignment is correct.
    1. Weld length - 98mmUse the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 35mm
    3. Weld around inside perimeter, minimise start/stop.

    Courtesy of FORD MOTOR COMPANY

11. Install the FESM mounting bracket in position and tack weld at 3 locations. Refer to: JOINING TECHNIQUES

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

    Courtesy of FORD MOTOR COMPANY

12. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joints completely if the alignment is correct.
    1. Weld length - 90mmUse the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 50mm
    3. Weld length - 72mm

    Courtesy of FORD MOTOR COMPANY

13. NOTE: Right hand (RH) shown, left hand (LH) similar.

    Loosely clamp the replacement bracket in a preliminary position. Perform measurements to verify proper placement of the new front bumper bracket, then clamp firmly into position.

    • With all measurements verified and the new front bumper bracket in proper position, tack-weld the new front bumper bracket in place to the frame crossmember.Use the General Equipment: MIG/MAG Welding EquipmentUse the General Equipment: Locking Pliers

    Courtesy of FORD MOTOR COMPANY

14. NOTE: Right hand (RH) shown, left hand (LH) similar.

    Re-check measurements, then solid weld the front bumper bracket to the frame crossmember.

    1. Weld length - 128mmUse the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 60mm

    Courtesy of FORD MOTOR COMPANY

15. Metal finish the repair area using typical metal finishing techniques.
16. Refinish using a Ford approved paint system. Refer to: PAINTWORK DEFECTS AND DAMAGE .
17. Restore corrosion protection. Refer to: CORROSION PREVENTION .
18. Sealing work: All areas must be sealed to production level. Refer to: SEALER, UNDERBODY PROTECTION MATERIAL AND ADHESIVES .

    Front Frame Section 

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

    Courtesy of FORD MOTOR COMPANY

20. Verify dimensional accuracy before  performing any welding operations. Refer to: BODY DIMENSIONS .
21. NOTE: Left hand (LH) shown, right hand (RH) similar.

    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 CONSTRUCTION . Refer to: JOINING TECHNIQUES

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

    Courtesy of FORD MOTOR COMPANY

22. NOTE: Left hand (LH) shown, right hand (RH) similar.

    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 CONSTRUCTION . Refer to: JOINING TECHNIQUES

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

    Courtesy of FORD MOTOR COMPANY

23. NOTE: LH side shown, RH side similar.

    If equipped, install the barrier tubes.

    Torque: 66 lb.ft (90 Nm)

    Courtesy of FORD MOTOR COMPANY

24. Metal finish the repair area using typical metal finishing techniques.
25. Refinish using a Ford approved paint system.
26. Restore corrosion protection. Refer to: CORROSION PREVENTION .
27. Install 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. Lower the engine and transmission assembly. Refer to: Engine Mount LH (303-01A Engine - 2.3L EcoBoost (199kW/270PS), . Refer to: Engine Mount LH (303-01B Engine - 2.7L EcoBoost (238kW/324PS), . Refer to: Engine Mount RH (303-01A Engine - 2.3L EcoBoost (199kW/270PS), . Refer to: Engine Mount RH (303-01B Engine - 2.7L EcoBoost (238kW/324PS), .
    7. Refer to: Lower Arm .
    8. Refer to: Upper Arm .
    9. Refer to: Steering Gear .
    10. Connect the exhaust system to 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), .
    11. Install the body-frame mounting bushes. Refer to: Frame and Body Mounting .

28. Remove the following items:
    1. Refer to: Radiator - 2.3L EcoBoost (199kW/270PS), . Refer to: Radiator - 2.7L EcoBoost (238kW/324PS), .
    2. Refer to: Front Bumper - Modular . Refer to: Front Bumper - Plastic .
    3. Refer to: Fender .
    4. On both sides. Refer to: Wheel and Tire .