Section 02-01: Frame | 1996 F-150, F-250, F-350, F-Super Duty Chassis Cab and Bronco Workshop Manual |
Cracks may appear in the frame (5005) at the frame side rail (5015) near the steering gear (3504) or steering gear bolt heads, or in the steering gear frame liner.
| Item | Part Number | Description |
|---|---|---|
| 1 | 3504 | Steering Gear |
| 2 | N803942-S100 | Bolt |
| 3 | 5015 | Frame Side Rail |
| 4 | 389564-S190 | Bolt |
| 5 | 388273-S101 | Washer |
| 6 | 3590 | Steering Gear Sector Shaft Arm |
| 7 | 380771 | Nut |
| A | — | Tighten to 41-57 Nm (30-42 Lb-Ft) |
| B | — | Tighten to 73-90 Nm (54-66 Lb-Ft) |
| C | — | Tighten to 230-310 Nm (170-228 Lb-Ft) |
The following areas of the frame should be checked before performing a steering gear frame liner repair.
If there are cracks in these areas of the frame, the frame must be replaced. Inspect the mounting surface of the steering gear for signs of motion, loose rivets or cracks. Removal of the steering gear may be necessary to check for cracks in the frame liner. Refer to Section 11-02C for procedure. If the frame liner is cracked or has loose rivets, repair the liner by using Frame Repair Kit E6TZ-5K130-A. If necessary, a steering gear line-to-frame rivet repair can be made by using the following procedures.
Rivet Removal and Replacement
Drill a 3mm (1/8-inch) hole through rivet.
Redrill the hole through the shank of the rivet with a 9mm (11/32-inch) drill.
Use an air chisel to remove rivet head.
Drive out rivet with a punch or other suitable tool.
Line drill one 11mm (7/16-inch) hole marked V to 14mm (9/16-inch) diameter.
Install one 14mm (9/16-inch) bolt in the direction shown in the following illustration.
Tack weld the nut to the bolt as shown in the above illustration.
Position bolt head on top (next to front crossmember (5019)) with hex-head flat to the rear to provide best clamping.
Install one 14mm (9/16-inch) washer nut side only and one 14mm (9/16-inch) nut. Tighten to 188-192 Nm (139-141 lb-ft).
Rivet Replacement with Bolts
If a flange head nut and bolt are not available, Grade 5 hex-heads may be substituted with one flatwasher required under the nut and one flatwasher required under the bolt head. Grade 8 bolts may be substituted for any application. Refer to the Bolt Selection Chart below.
| Rivet Diameter | Bolt Size | Bolt Part Number | Washer Part Number | Nut Part Number | Torque Specs. |
|---|---|---|---|---|---|
| 3/8-Inch and 10mm | 7/16-14x1.25 | 56561-S2 (Class S) | Not Req. | 382400-S2 (Class RG) | 33-50 Lb-Ft (45-68 Nm) |
| 3/8-Inch and 10mm | 7/16-14x1.75 | 56563-S2 (Class C) | Not Req. | 382400-S2 (Class RG) | 33-50 Lb-Ft (45-68 Nm) |
| 7/16-Inch | 1/2-13x1.5 (Grade 5) | 56783-S100 (Class C) | Not Req. | 33773-S2 (Class S) | 53-75 Lb-Ft (72-102 Nm) |
| 7/16-Inch | 1/2-13x2.0 (Grade 8) | 383896-S2 (Class BS) | 44879-S2 (Class BS) | 33773-S2 (Class S) | 75-105 Lb-Ft (102-142 Nm) |