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Technical Information
Advantage Online
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FORD FULL FRAME REPAIR CONFUSION
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Figure 1-Tech-Cor bulletin 2000-1 refers to a front frame sectioning repair on this F-150 Ford. This repair should NOT be made.
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May 6, 2002 -What are the recommended front frame repairs to Ford full-frame vehicles? The confusion is between a recent Tech-Cor bulletin on repairs to the Light-Duty truck platform (see Figure 1), an older Tech-Cor bulletin on frame sectioning (see Figure 2), and a Ford-approved procedure on another truck platform.
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Figure 2-Tech-Cor bulletin 1999-1 references a front frame horn sectioning procedure that is NOT sanctioned by Ford Motor Company.
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Tech-Cor, a research and testing facility, published a recent bulletin regarding problems experienced when replacing a front frame portion on 1997-2001 Ford 4x4 and 4x2 Light-Duty F-150/250 pickup trucks and Super Cab and Super Crew trucks (Bulletin #2001-1). This bulletin is not to be confused with a front frame replacement kit available from Ford for the Super-Duty F-Series, which consists of the F-250, F-350, F-450, and F-550 models.
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Figure 3-This factory seam on the Light-Duty F-150 frame is NOT a cut location for a repair joint.
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Tech-Cor bulletin #2001-1 discusses the testing of a procedure that involves removing and replacing the front portion of the Light-Duty frame from a factory seam underneath the passenger compartment (see Figure 3). This part is not available as a service part from Ford Motor Company. After the repair was made, Tech-Cor crash-tested the pickup truck and found that, due to a bracket mounted underneath the cab, the fuel tank was punctured, causing a fuel leak. This type of repair to the front frame on these vehicles should NOT be performed.
This bulletin does NOT affect the front frame section repair from Ford for the Super-Duty F-Series.
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Figure 4-The Tech-Cor frame horn sectioning procedure involves replacing the frame rail forward of the steering gear mounting area.
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What may have added to the confusion is other published information on repairs to Ford full frames, including another Tech-Cor bulletin, and the May-June 1999 issue of the I-CAR Advantage. Tech-Cor bulletin #1999-1 pertains to a replacement procedure for the left front frame horn, forward of the steering gear mounting area, on 1997-1999 Ford 4x4 Light-Duty F-150/250 pickup trucks and Expedition and the 1998-1999 Lincoln Navigator (see Figure 4). This bulletin references a different frame replacement procedure and is not related to Bulletin #2001-1. Additionally, the front frame horn replacement procedure does not apply to 4x2 models or the Ford Super-Duty F-Series vehicles.
I-CAR Advantage Full-Frame Article
The article on Ford Full Frames in the May-June 1999 issue has proven to be a popular article, so popular it was made available free on the I-CAR web site long before other issues were made available. Key points to this article include:
- do NOT repair the crush initiators on 1996 and later Explorer and F-150 frames. This area is from the front to about 600 mm (24") back. If the frame is bent in this area, straightening is not an option. Ford maintains that the integrity of these areas is crucial to proper airbag deployment, and therefore these areas should not be repaired.
- heat recommendations are that if heat must be applied to relieve stress in structural parts, the hot working temperature should not exceed 650oC (1,200oF). If more than the allowable amount of heat is necessary to straighten a bent frame rail, that's an indication that It’s too severely bent to straighten. This does NOT apply to the front crush initiators.
- Ford agrees that the I-CAR kink vs. bend rule should apply to frame assemblies, other than the front crush initiators.
- the center section of the 1996 and newer F-150 is specified to be high-strength steel, at least 50,000 psi minimum yield strength. The front and rear sections are specified to be at least 36,000 psi minimum yield strength, which is classified as mild steel. The steel that is delivered to Ford may range from the minimum specified to a higher yield strength. This means that although a mild steel specification is given, the yield strength will typically range from 40,000-42,000 psi. This reinforces a longtime I-CAR general rule when working with steel: treat it all like high-strength steel.
Summary Of Published Repairs To Ford Full Frames
To help simplify which procedure applies to the appropriate Ford full-frame model, here's a summary.
Sectioning procedures sanctioned by Ford Motor Company include the following.
Front frame horn extensions (right and left replacement sections):
- 1992-1995 Explorer
- 1992-1997 Ranger
- 1992 and later Econoline Van
Front frame sectioning:
- 1997 and later F-250, F-350, F-450, F-550 Super-Duty
- 2000 and later Excursion
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Figure 5-Ford Motor Company offers a service part to section the rear part of the frame on mid-1999 and later Expeditions and Navigators.
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Rear frame sectioning:
- Mid-1999 and later Expedition and Navigator (see Figure 5)
Tech-Cor bulletin #1999-1 (Front Frame Horn Replacement):
(Note: This procedure is NOT sanctioned by Ford Motor Company)
- 1997-1999 Ford F-150, 4x4, Light-Duty
- 1997-1999 Ford F-250, 4x4, Light-Duty
- 1997-1999 Ford Expedition, 4x4
- 1998-1999 Lincoln Navigator
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