Frame Extension - Stub Frame, Front: Removal

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: LH side of front stub frame extension shown, RH side similar.

Prepare the vehicle for front stub frame extension removal.
- Remove the front bumper/body.
- Vehicles with automatic transmission, remove the transmission. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT article.
- Vehicles with manual transmission, remove the transmission. For additional information, refer to FOUR WHEEL DRIVE (4WD) SYSTEMS article or TRANSFER CASE article.
- Remove the engine. For additional information, refer to ENGINE - 5.4L (3V) article, ENGINE - 6.8L (3V) article or ENGINE - 6.0L DIESEL article.
- Remove the exhaust system components as necessary to access the front stub-to-reinforcement rivets. For additional information, refer to EXHAUST SYSTEM article.
- Remove the power steering gear and any steering components attached to the frame. For additional information, refer to POWER STEERING article.
- Vehicles with 4-wheel drive, remove the front drive axle. For additional information, refer to FRONT DRIVE AXLE/DIFFERENTIAL article.
- Vehicles with 2-wheel drive, remove the front axle. For additional information, refer to FRONT SUSPENSION - REAR WHEEL DRIVE (RWD) article.
- Remove all suspension components attached to the front stub frames including the front leaf spring rear shackle bracket or the radius arm pivot bracket. For additional information, refer to FRONT SUSPENSION - REAR WHEEL DRIVE (RWD) article or FRONT SUSPENSION - FOUR WHEEL DRIVE (4WD) article.

CAUTION: Before this step is carried out, the reinforcement and surrounding frame area must be correctly prepared.

Remove and discard the rivets used to secure the side rail reinforcements to the front stub frame and rear side rail. Separate the weld joints. For additional information, refer to Rivet Replacement in this section.

Fig 1: Locating Rivets (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Locating Rivets (2 Of 2)

Courtesy of FORD MOTOR CO.

Remove the front stub assembly and the side rail reinforcement at the joint.