Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2002 Ford Excursion 4WD V10-6.8LFACTORY OEM SERVICE PROCEDURE
Frame Extension: Service and Repair
FRAME EXTENSION-STUB FRAME, FRONT
Removal
NOTE: The LH side of the front stub frame extension is shown, the RH side is similar.
1. Prepare the vehicle for front stub frame extension removal.
1 Remove the front bumper body.
2 Vehicles with automatic transmission. remove the transmission.
3 Vehicles with manual transmission, remove the transmission.
4 Remove the engine.
5 Remove the exhaust system components as necessary to access the front stub-to-reinforcement rivets.
6 Remove the power steering gear and any steering components attached to the frame.
7 Vehicles with 4-wheel drive, remove the front drive axle.
8 Vehicles with 2-wheel drive, remove the front axle.
9 Remove all suspension components attached to the front stub frames including the front leaf spring rear shackle bracket or the radius arm pivot bracket.
2. CAUTION: Before this step is carried out, the reinforcement and surrounding frame area must be correctly prepared.
Remove and discard the rivets used to secure the side rail reinforcements to the front stub frame and rear side rail. Separate the weld joints.
3. Remove the front stub assembly and the side rail reinforcement at the joint.
Installation
1. NOTE:
- Refer to Specifications for parts identification when installing new stub frames and side rail reinforcements. Specifications
- The side rail reinforcement must be attached to the rear stub frame first during installation.
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.
3. NOTE: The side rail reinforcement must attached to the rear side rails first during installation.
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.
4. Restore the vehicle to operating condition.
1 Install all suspension components that were removed.
2 Vehicle with 2-wheel drive, install the front axle.
3 Vehicles with 4-wheel drive, install the front drive axle.
4 Install the power steering components that were removed.
5 Install the exhaust system components that were removed.
6 Install the engine.
7 Vehicles with manual transmission, install the transmission.
8 Vehicles with automatic transmission, install the transmission.
9 Install the front bumper body.
Removal
NOTE: The LH side of the front stub frame extension is shown, the RH side is similar.
1. Prepare the vehicle for front stub frame extension removal.
1 Remove the front bumper body.
2 Vehicles with automatic transmission. remove the transmission.
3 Vehicles with manual transmission, remove the transmission.
4 Remove the engine.
5 Remove the exhaust system components as necessary to access the front stub-to-reinforcement rivets.
6 Remove the power steering gear and any steering components attached to the frame.
7 Vehicles with 4-wheel drive, remove the front drive axle.
8 Vehicles with 2-wheel drive, remove the front axle.
9 Remove all suspension components attached to the front stub frames including the front leaf spring rear shackle bracket or the radius arm pivot bracket.
2. CAUTION: Before this step is carried out, the reinforcement and surrounding frame area must be correctly prepared.
Remove and discard the rivets used to secure the side rail reinforcements to the front stub frame and rear side rail. Separate the weld joints.
3. Remove the front stub assembly and the side rail reinforcement at the joint.
Installation
1. NOTE:
- Refer to Specifications for parts identification when installing new stub frames and side rail reinforcements. Specifications
- The side rail reinforcement must be attached to the rear stub frame first during installation.
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.
3. NOTE: The side rail reinforcement must attached to the rear side rails first during installation.
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.
4. Restore the vehicle to operating condition.
1 Install all suspension components that were removed.
2 Vehicle with 2-wheel drive, install the front axle.
3 Vehicles with 4-wheel drive, install the front drive axle.
4 Install the power steering components that were removed.
5 Install the exhaust system components that were removed.
6 Install the engine.
7 Vehicles with manual transmission, install the transmission.
8 Vehicles with automatic transmission, install the transmission.
9 Install the front bumper body.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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