Section 02-01: Frame
1996 F-150, F-250, F-350, F-Super Duty Chassis Cab and Bronco Workshop Manual
SERVICE PROCEDURES

Frame Side Rail to Rear Shock Bracket

Cracks may develop in the frame side rail (5015) at the rear shock absorber bracket rivets if the vehicle is used for continuous off-road service. If it is determined that a repair must be made, a reinforcement kit (F0TA-5L005-BA) for repair of frame (5005) is available.

  1. Position the vehicle on supports. Remove rear wheels and inspect rear shock absorber bracket (18192) for cracks and/or damage.

  1. Disconnect rear shock absorber (18125) from upper and lower mounting points. Locate the crack and clean the surface. A crack that has traveled past the midpoint of the side rail bend radius should not be repaired; a new frame is required. Refer to Frame Member Replacement. If the crack has not traveled past the midpoint of the side rail bend radius, the frame can be repaired. Use the following procedure for repair.

  1. Remove any tubes (2265) in the damaged area.

  1. Remove three rivets attaching rear shock absorber bracket to frame side rail. Use the following procedure to remove rivets.

    1. Drill a 3mm (1/8-inch) hole through rivet.
    1. Drill same hole with a 9mm (11/32-inch) drill through shank.
    1. Use an air chisel to remove head.
    1. Drive out rivet with a punch.

  1. Clean affected area with a wire brush.

  1. To repair, drill a 5mm (3/16-inch) hole at the crack termination into the side rail.

  1. Grind out a groove along the crack, top and bottom, one quarter of metal thickness deep.

  1. Run a continuous weld along groove. Weld direction is away from hole. Weld both sides and fill crack termination hole.

  1. Grind all weld deposits flush with side rail metal.

  1. Place the reinforcement plate over the outside of the side rail.

  1. Drilling from the inside out, use the rear shock absorber bracket holes in the frame side rail as a guide and line drill through the frame side rail and plate with a 12mm drill bit. Drill the rear shock absorber bracket mounting holes to 12mm (1/2 inch).

  1. Install the rear shock absorber bracket using 12mm (1/2-inch) fasteners and nuts. Place bolt head to outside, nut to inside of frame rail. Tighten to 118-122 Nm (88-89 lb-ft).

  1. NOTE: Refer to the instruction sheet in the frame reinforcement kit for proper weld locations.

    Weld plate to rail.

  1. Paint repaired area after cooling. Reinstall the rear shock absorber. Install the wheel and remove vehicle from supports.