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Frame Members-Front Frame Section: Removal

NOTE: The following procedure provides steps to replace the front frame short section at the first frame crossmember or the frame section at the center rail joint depending on the extent of vehicle damage.
  1. Restore the vehicle to manufacturer's dimensions. Refer to: BODY AND FRAME .

    All vehicles 

  2. Remove the following items:

    1. Refer to: Front Bumper .
    2. Refer to: Fender .
    3. Unbolt the Front End Sheet Metal (FESM) body mount bolts and raise or remove the body if required. Refer to: Frame and Body Mounting  .

  3. Anchor the vehicle to a frame rack following the equipment manufacturer's instructions.

    Front Frame Short Section 

    NOTE: This section of the frame

    MUST NOT be straightened if any holes or surfaces show evidence of collapse or buckling. If any evidence of damage exists BEHIND  the first frame cross member in terms of buckling, cracking, etc. then the entire front frame section or entire frame must be replaced.

  4. 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.

    Front frame short section overview.

    GFD546696Courtesy of FORD MOTOR COMPANY
  5. NOTE: Do not cut directly along the center of the weld line. Leave enough material on the front side of the weld centerline to allow the remaining weld and frame material to be ground back to the front edge of the front mid rail. This is necessary to make sure of correct fit between the frame and the replacement frame section.
    NOTE: LH side shown, RH side similar.

    Locate the vertical weld of the front frame to center rail, using a plasma cutter, reciprocating saw or cut-off wheel cut through the frame rail. Use the General Equipment: Grinder Use the General Equipment: Plasma Cutter

    GFD546697Courtesy of FORD MOTOR COMPANY
  6. Remove the frame section from the affected side.
    GFD546698Courtesy of FORD MOTOR COMPANY
  7. NOTE: Do not thin out the frame rail. The material must maintain a minimum thickness of 3.1 mm (0.12 in) after grinding. This is required to maintain correct energy management in the event of a collision.

    Grind off the excess welding material that remains around the perimeter of the front edge of the front frame rail of the frame assembly, and remove the remaining portion of the frame section from inside the frame rail. Use the General Equipment: Locking Pliers

    GFD546699Courtesy of FORD MOTOR COMPANY
  8. Using a wire brush or sandpaper, remove the e-coat paint from the existing frame near the edges to be welded on the inner and outer surfaces within approximately 15 mm (0.5 in.) of the repair joint.
    GFD546700Courtesy of FORD MOTOR COMPANY

    Front Frame Section 

    NOTE: The front frame section on this vehicle is retained by welded lap joints. The frame section will be removed and installed by grinding of the original welded joints, followed by welding of the new section into position.
  9. Front frame section overview.
    GFD546701Courtesy of FORD MOTOR COMPANY
  10. Remove the following items:

    1. Refer to: Transmission Support Crossmember  .
    2. If equipped. Refer to: Front Driveshaft .
    3. If equipped.
    4. Refer to: Shock Absorber and Spring Assembly 4WD . Refer to: Shock Absorber and Spring Assembly RWD .
    5. Raise and support the engine and transmission assembly. Refer to: Engine Mount RH 3.5L EcoBoost . Refer to: Engine Mount LH 3.5L EcoBoost .
    6. Remove the lower control arm, if equipped with 2WD. Refer to: Lower Arm RWD .
    7. Remove the lower control arm, if equipped with 4WD. Refer to: Lower Arm 4WD .
    8. Remove the upper control arm, if equipped with 2WD. Refer to: Upper Arm RWD .
    9. Remove the upper control arm, if equipped with 4WD. Refer to: Upper Arm 4WD .
    10. Refer to: Steering Gear .
    11. Disconnect the exhaust system for the engine. Refer to: Catalytic Converter RH 3.5L EcoBoost . Refer to: Catalytic Converter LH 3.5L EcoBoost .

  11. Loosen the body mount to frame bushing bolts from the radiator support and the forward cab support.
  12. Disconnect and remove any remaining wiring, lines, and related fittings from the frame section.
  13. Grind through the original welded joints retaining the forward frame section to the center section. Be careful not to cut into the center side rail since it will be reused.

    • Using a chisel gun with a sharp 25.4 mm (1 inch) wide wedge chisel, separate the ground area of the joints. Use the General Equipment: Grinder

    GFD546702Courtesy of FORD MOTOR COMPANY
  14. With the help of an assistant, remove the complete front frame section.
    GFD546703Courtesy of FORD MOTOR COMPANY
  15. NOTE: Do not thin out the frame rail. The material must maintain a minimum thickness of 3.1 mm (0.12 in) after grinding. This is required to maintain correct energy management in the event of a collision.

    Grind off the excess welding material that remains around the perimeter of the front edge of the mid frame rail of the frame assembly, and remove the remaining portion of the frame section from inside the frame rail.

  16. Using a wire brush or sandpaper, remove the e-coat paint from the existing frame near the edges to be welded on the inner and outer surfaces within approximately 15 mm (0.5 in.) of the repair joint.
GFD546704Courtesy of FORD MOTOR COMPANY
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