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Frame Extension - Stub Frame, Front: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Refer to SPECIFICATIONS . for parts identification when installing new stub frames and side rail reinforcements.
  1. Prepare the frame in order to make sure of a good weld adhesion.
    1. Using a heat gun, warm up the area in order to soften the frame wax coating. Completely clean the surface of the frame rail under and around the center rail. Use a razor blade in handle to remove all of the frame wax.
    2. Use a wax and grease remover for final cleaning of the remaining wax residue.
    3. Use a 3-inch grinder to remove the paint from the top flange of the front rail in the areas to be welded.
  2. Position the new center rail and align the attaching holes with the front and rear rails.
  3. Using the center rail as a template, drill a hole through all of the attaching holes to the replacement bolt nominal size, with a hole tolerance of ±0.005 inch.
  4. After drilling, remove any burrs from the holes in order to allow the bolt head and nut to seat correctly.
    5. NOTE: The side rail reinforcement must be attached to the rear stub frame first during installation.
  5. Position the front stub assembly and the side rail reinforcements on the frame assembly.
    6. NOTE: Install the nuts and bolts so that the nuts are located on the outside of the frame.
  6. Secure the center rail with new nuts (382400-S2) and bolts (391330-S2). Apply Threadlock 262 or equivalent to the bolts before installing the nuts.
    • Tighten all fasteners to 53 Nm (39 lb-ft).
      Fig 1: Locating Center Rail Nuts
      G04646734Courtesy of FORD MOTOR CO.
      Fig 2: Locating Center With Rail Nuts
      G04646735Courtesy of FORD MOTOR CO.
    7. NOTE: The side rail reinforcement must be attached to the rear side rails first during installation.
    NOTE: To minimize stress concentrations, do not weld at the corners. For additional information, refer to RIVET REPLACEMENT .
  7. Weld the side rail reinforcement to the front stub frame and the rear side rails.
    • Plug weld the top frame flange to the center rail.
    • Stitch weld the front rail to the rear rail.
      Fig 3: Locating Stitch Weld Front Rail To Rear Rail
      G04646736Courtesy of FORD MOTOR CO.
  8. Restore the vehicle to operating condition.
    1. Install all suspension components that were removed. For additional information, refer to FRONT SUSPENSION - REAR WHEEL DRIVE (RWD) or FRONT SUSPENSION - FOUR WHEEL DRIVE (4WD) .
    2. Vehicle with 2-wheel drive, install the front axle. For additional information, refer to FRONT SUSPENSION - REAR WHEEL DRIVE (RWD) .
    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 (4WD) 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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