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Home >> Ford >> 2021 >> Bronco Base, 2D Utility, 2.3L Eng VIN H, Part Time T/Case Control, Automatic Trans >> Repair and Diagnosis (Single Page) >> Body & Frame >> Frames, Subframes & Crossmembers >> Full Frame And Body Mounting >> Removal And Installation >> Frame Members-Front Frame Section >> Installation
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Frame Members-Front Frame Section: Installation

Front Frame Short Section 

NOTE: Right hand (RH) shown in illustration, left hand (LH) similar.
  1. Verify dimensional accuracy before performing any welding operations. Refer to: BODY DIMENSIONS AND BODY CONSTRUCTION .
  2. Sealer or adhesive must be applied with a minimum height of 6 mm. Refer to: SEALER, UNDERBODY PROTECTION MATERIAL AND ADHESIVES .
  3. NOTE: The replacement front frame components are production parts designed with a taper to insert into the front rail section to assist in alignment and welding operations.
    NOTE: Check that the Front End Sheet Metal (FESM) body mount bracket lines up with the sheet metal hole for the body mount bolt.

    Install the front frame section inside the mid front rail of the frame and tack weld at 4 locations. Refer to: JOINING TECHNIQUES .

    Use the General Equipment: MIG/MAG Welding Equipment

    Use the General Equipment: Locking Pliers

    GFD628813Courtesy of FORD MOTOR COMPANY
  4. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joint completely if this alignment is correct. Use the General Equipment: MIG/MAG Welding Equipment
    GFD628814Courtesy of FORD MOTOR COMPANY
  5. Install the SORB bracket replacement assembly in position and tack weld at 4 locations. Refer to: JOINING TECHNIQUES .

    Use the General Equipment: MIG/MAG Welding Equipment

    Use the General Equipment: Locking Pliers

    GFD628815Courtesy of FORD MOTOR COMPANY
  6. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joint completely if this alignment is correct. Use the General Equipment: MIG/MAG Welding Equipment
    GFD628816Courtesy of FORD MOTOR COMPANY
  7. Install the SORB gusset bracket replacement assembly in position and tack weld at 2 locations at the top. Refer to: JOINING TECHNIQUES .

    Use the General Equipment: MIG/MAG Welding Equipment

    Use the General Equipment: Locking Pliers

    GFD628817Courtesy of FORD MOTOR COMPANY
  8. Hold the SORB gusset bracket replacement assembly in same position and tack weld at 2 locations at the bottom. Refer to: JOINING TECHNIQUES .

    Use the General Equipment: MIG/MAG Welding Equipment

    Use the General Equipment: Locking Pliers

    GFD628818Courtesy of FORD MOTOR COMPANY
  9. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joints completely if the alignment is correct.

    1. Weld length - 50mm Use the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 68mm
    3. Weld around inside perimeter, minimise start/stop.

    GFD628819Courtesy of FORD MOTOR COMPANY
  10. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joints completely if the alignment is correct.

    1. Weld length - 98mm Use the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 35mm
    3. Weld around inside perimeter, minimise start/stop.

    GFD628820Courtesy of FORD MOTOR COMPANY
  11. Install the FESM mounting bracket in position and tack weld at 3 locations. Refer to: JOINING TECHNIQUES .

    Use the General Equipment: MIG/MAG Welding Equipment

    Use the General Equipment: Locking Pliers

    GFD628821Courtesy of FORD MOTOR COMPANY
  12. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joints completely if the alignment is correct.

    1. Weld length - 90mm Use the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 50mm
    3. Weld length - 72mm

    GFD628822Courtesy of FORD MOTOR COMPANY
  13. NOTE: Right hand (RH) shown in illustration, left hand (LH) similar.

    Loosely clamp the replacement bracket in a preliminary position. Perform measurements to verify proper placement of the new front bumper bracket, then clamp firmly into position.

    • With all measurements verified and the new front bumper bracket in proper position, tack-weld the new front bumper bracket in place to the frame crossmember.

      Use the General Equipment: MIG/MAG Welding Equipment

      Use the General Equipment: Locking Pliers

    GFD628823Courtesy of FORD MOTOR COMPANY
  14. NOTE: Right hand (RH) shown in illustration, left hand (LH) similar.

    Re-check measurements, then solid weld the front bumper bracket to the frame crossmember.

    1. Weld length - 128mm Use the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 60mm

    GFD628824Courtesy of FORD MOTOR COMPANY
  15. Metal finish the repair area using typical metal finishing techniques.
  16. Refinish using a Ford approved paint system. Refer to: PAINTWORK DEFECTS AND DAMAGE .
  17. Restore corrosion protection. Refer to: CORROSION PREVENTION .
  18. Sealing work: All areas must be sealed to production level. Refer to: SEALER, UNDERBODY PROTECTION MATERIAL AND ADHESIVES .

    Front Frame Section 

  19. With the help of an assistant, position the new front frame section into place on the vehicle.
    GFD628825Courtesy of FORD MOTOR COMPANY
  20. Verify dimensional accuracy before  performing any welding operations. Refer to: BODY DIMENSIONS AND BODY CONSTRUCTION .
  21. NOTE: Left hand (LH) shown in illustration, right hand (RH) similar.

    Support the new section, and loosely clamp the replacement section in a preliminary position.

    GFD628826Courtesy of FORD MOTOR COMPANY
  22. NOTE: Left hand (LH) shown in illustration, right hand (RH) similar.

    Support the new section, and loosely clamp the replacement section in a preliminary position.

    GFD628827Courtesy of FORD MOTOR COMPANY
  23. NOTE: LH side shown in illustration, RH side similar.

    If equipped, install the barrier tubes.

    Torque

    : 66 lb.ft (90 Nm)

    GFD628828Courtesy of FORD MOTOR COMPANY
  24. Metal finish the repair area using typical metal finishing techniques.
  25. Refinish using a Ford approved paint system.
  26. Restore corrosion protection. Refer to: CORROSION PREVENTION .
  27. Install the following items:

    1. Refer to: Transmission Support Crossmember - 2.3L EcoBoost (199kW/270PS) . Refer to: Transmission Support Crossmember - 2.7L EcoBoost (238kW/324PS) .
    2. If equipped. Refer to: Front Driveshaft .
    3. If equipped. Refer to: Halfshaft .
    4. Refer to: Shock Absorber and Spring Assembly .
    5. Refer to: Front Stabilizer Bar .
    6. Lower the engine and transmission assembly. Refer to: Engine Mount LH - 2.3L EcoBoost (199kW/270PS). Refer to: Engine Mount LH - 2.7L EcoBoost (238kW/324PS). Refer to: Engine Mount RH - 2.3L EcoBoost (199kW/270PS). Refer to: Engine Mount RH - 2.7L EcoBoost (238kW/324PS).
    7. Refer to: Lower Arm .
    8. Refer to: Upper Arm .
    9. Refer to: Steering Gear .
    10. Connect the exhaust system to the engine. Refer to: Catalytic Converter - 10-Speed Automatic Transmission - 10R60 - 2.3L EcoBoost (199kW/270PS). Refer to: Catalytic Converter - 7-Speed Manual Transmission - MT88 - 2.3L EcoBoost (199kW/270PS). Refer to: Catalytic Converter LH - 2.7L EcoBoost (238kW/324PS). Refer to: Catalytic Converter RH - 2.7L EcoBoost (238kW/324PS).
    11. Install the body-frame mounting bushes. Refer to: Frame and Body Mounting .

  28. Remove the following items:

    1. Refer to: Radiator - 2.3L EcoBoost (199kW/270PS). Refer to: Radiator - 2.7L EcoBoost (238kW/324PS).
    2. Refer to: Front Bumper - Modular . Refer to: Front Bumper - Plastic .
    3. Refer to: Fender .
    4. On both sides. Refer to: Wheel and Tire .

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