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.
Frame Members-Rear Frame Section: Installation
- Refer to: Joining Techniques .
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NOTE: Verify dimensional accuracy before performing any welding operations.
Install the new rear frame section into the mid rear section of the frame and tack weld the frame rails. Refer to BODY REPAIRS (TOLERANCE CHECKS) .
- Perform a final measurement, then final weld the new rear section to the mid rear section on all overlap joints on both sides. Use the General Equipment: MIG/MAG Welding Equipment
- Metal finish the joint area typical metal finishing techniques.
- Position the upper and lower reinforcements and clamp in place on both sides. Use the General Equipment: Locking Pliers
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NOTE: Reinforcement welds skip over frame rail joint.
Weld the upper and lower reinforcements to the outer mid rear and rear frame section LH and RH sides.
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NOTE: Reinforcement welds skip over frame rail joint and do not go around the frame rail inboard corners.
Weld the upper and lower reinforcements to the inner mid rear and rear frame section LH and RH sides.
- Metal finish the joint area typical metal finishing techniques.
- Refinish using a Ford approved paint system.
- Restore corrosion protection. Refer to: Corrosion Prevention .
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NOTE: To avoid damage to the spare tire winch when installing the spare tire, DO NOT exceed 200 RPM if using power tool equipment.
Install the following items:
- As equipped. Refer to: Fuel Tank Filler Pipe . . Refer to: Fuel Tank Filler Pipe . Refer to: Fuel Tank Filler Pipe . . Refer to: Fuel Tank Filler Pipe .
- As equipped. Refer to MUFFLER AND TAILPIPE
- Refer to SPRING
- Refer to Rear Shock Absorber
- Refer to PICKUP BED AND PLATFORM BODY
- Refer to Rear Bumper
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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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.