Frame Members

Front Side Members — Exploded View

NOTE: Right side shown, left side similar.

 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: 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.

 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.

NOTE: Observe prescribed welding procedures when carrying out any repair to unibody/frame structure. For additional information, refer to Welding Precautions — Steel in this section.

1. Remove the hood.

2. 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. If necessary, rough pull the vehicle to restore the vehicle to pre-accident dimensions. For additional dimensional information, refer to Body in this section.
   • Remove the front bumper. For additional information, refer to Section 501-19 .

3. Remove the battery. For additional information, refer to Section 414-01 .

4. Remove the fender(s) from the affected side(s). For additional information, refer to Section 501-02 .

5. Remove the radiator. For additional information, refer to Section 303-03 .

6. Remove the radiator bolster assembly. For additional information, refer to Section 501-02 .

7. Remove the subframe, powertrain and drivetrain assemblies as required. For additional information, refer to Section 502-00 , and Section 307-01 .

8. Remove the suspension components as required. For additional information, refer to Section 204-01 .

9. NOTE: Factory spot welds may be substituted with either Squeeze-Type Resistance Spot Welding (STRW) 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.

   Drill out the spot welds and remove the subframe mount bracket assembly from the affected side(s).

10. NOTE: The following 3 steps illustrate the 3 cut-points that can be used when carrying out repairs, depending on severity of collision damage. Choose the appropriate cut-point as necessary.

    NOTE: Cut point No. 1. LH shown, RH similar.

    Scribe a cut-line 155 mm (6.1 in) from the front bumper bracket on the outer frame rail. Using a plasma cutter, cut-off wheel or reciprocating saw, cut off the front rail inner and outer assemblies along the scribe line.
    • Scribe a cut-line 40 mm (1.57 in) to 50 mm (1.96 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.
    • Dress the weld surfaces.

11. NOTE: Cut point No. 2. LH shown, RH similar.

    Scribe a cut-line 330 mm (12.99 in) from the front bumper bracket on the outer frame rail. Using a plasma cutter, cut-off wheel or reciprocating saw, cut off the front rail inner and outer assemblies along the scribe line.
    • Scribe a cut-line 40 mm (1.57 in) to 50 mm (1.96 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.
    • Dress the weld surfaces.

12. NOTE: Cut point No. 3. LH shown, RH similar.

    Scribe a cut-line 870 mm (34.25 in) from the front bumper bracket on the outer frame rail. Using a plasma cutter, cut-off wheel or reciprocating saw, cut off the front rail inner and outer assemblies along the scribe line.
    • Scribe a cut-line 40 mm (1.57 in) to 50 mm (1.96 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.
    • Dress the weld surfaces.

13. Chamfer the inner and outer rail cut line surfaces to improve butt weld condition.

14. Transcribe the rail inner and outer cut-line to the new front rail inner and outer rail(s).

15. Using a plasma cutter, cut-off wheel or reciprocating saw, cut to length. Chamfer the surface ends to improve weld surface.

16. Using a wire brush or sandpaper, remove the E-coat from the outer surfaces of the replacement service section within approximately 15 mm (0.59 in) of the repair joint.
    • Using a wire brush, remove any foreign material from the frame within approximately 15 mm (0.59 in) of the repair joint. Prepare all bare metal surfaces with metal surface prep and a weld-through primer.

17. Install and clamp the service replacement inner frame rail in place. Tack weld and verify correct alignment of the frame rail.

18. Seam weld along the inside of the section joint using a MIG welder and ER70S-3 wire 0.9 mm (0.035 in) to 0.11 mm (0.045 in) diameter.
    • Verify correct alignment and underbody dimensions.

19. Use a dye penetrant to determine if any cracks or large voids exist in the weld joint. If cracks or other defects exist, grind out the defect and repair until the weld is free of defects.
    • Clean the repair area with metal surface prep and apply corrosion protection to the affected area.
    • Clean the service replacement outer frame rail and apply anti-corrosion protection.

20. Install and clamp the service replacement outer frame rail in place.
    • Verify correct alignment of the outer frame rail.

21. Seam weld along the section joint of the outer frame rail using a MIG welder and ER70S-3 wire 0.9 mm (0.035 in) to 1.1 mm (0.045 in) diameter.

22. Use a dye penetrant to determine if any cracks or large voids exist in the weld joint. If cracks or other defects exist, grind out the defect and repair until the weld is free of defects.
    • Clean the repair area with metal surface prep and apply corrosion protection to the affected area.

23. NOTE: Factory spot welds may be substituted with either STRW 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 or spot weld along the top and bottom seam of the service replacement rails.

24. Install the subframe mount bracket assembly if previously removed.

25. Dress the welds as necessary and apply anti-corrosion protection.

26. Reinstall the subframe and powertrain components if removed during disassembly. For additional information, refer to Section 502-00 , and Section 307-01 .
    • Add 2 additional spot welds for the subframe attachment bracket assembly and install weld nut W711013-S300 (left side sub-assembly only). Apply corrosion protection to the affected areas of the frame and service replacement section.

27. Reinstall the radiator bolster assembly. For additional information, refer to Section 501-02 .

28. Reinstall the radiator. For additional information, refer to Section 303-03 .

29. Reinstall the battery. For additional information, refer to Section 414-01 .

30. Reinstall the fender(s). For additional information, refer to Section 501-02 .

31. Reinstall the front bumper. For additional information, refer to Section 501-19 .

32. Reinstall the hood.