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Frame Extension - Stub Frame, Front: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Refer to SPECIFICATIONS  in this article for parts identification when installing new stub frames and side rail reinforcements.
    NOTE: The side rail reinforcement must be attached to the rear stub frame first during installation.
  1. Position the front stub assembly and the side rail reinforcements on the frame assembly.
  2. Install new bolts, washers and nuts of the same size as the rivets that were removed.
    Fig 1: Installing New Bolts, Washers And Nuts (1 Of 2)
    G03912161Courtesy of FORD MOTOR CO.
    Fig 2: Installing New Bolts, Washers And Nuts (2 Of 2)
    G03912162Courtesy of FORD MOTOR CO.
    3. NOTE: The side rail reinforcement must be attached to the rear side rails first during installation.
    Fig 3: Identifying Weld Areas
    G03912163Courtesy of FORD MOTOR CO.
  3. Weld the side rail reinforcement to the front stub frame and the rear side rails following good weld application techniques. Do not weld at the corners to minimize stress concentrations. For additional information, refer to Rivet Replacement  in this article.
  4. Restore the vehicle to operating condition.
    1. Install all suspension components that were removed. For additional information, refer to FRONT SUSPENSION - 4X2 or FRONT SUSPENSION - 4X4 .
    2. Vehicle with 2-wheel drive, install the front axle. For additional information, refer to FRONT SUSPENSION - 4X2 .
    3. Vehicles with 4-wheel drive, install the front drive axle. For additional information, refer to FRONT DRIVE AXLE/DIFFERENTIAL .
    4. Install the power steering components that were removed. For additional information, refer to POWER STEERING .
    5. Install the exhaust system components that were removed. For additional information, refer to EXHAUST SYSTEM .
    6. Install the engine. For additional information, refer to ENGINE - 5.4L (3V) , ENGINE - 6.8L (3V) or ENGINE - 6.0L DIESEL .
    7. Vehicles with manual transmission, install the transmission. For additional information, refer to FOUR- WHEEL DRIVE SYSTEMS or TRANSFER CASE .
    8. Vehicles with automatic transmission, install the transmission. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT .
    9. Install the front bumper/body.
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