Collision Repair Training | Australia
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Collision Repair Training | Australia
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Current Events/News: Advantage Online: 2003 Archives
FORD MOTOR COMPANY INTRODUCES 2004 F-150 WITH CHANGES
Front Frame Rail Sectioning Procedure
The 2004 F-150 offers a right and left front frame rail sectioning procedure. The frame section and repair instructions are available as a kit from Ford Motor Company (see Figure 2). This repair is an option to full-frame replacement. This joins the 1992–1995 Explorer, 1992–1997 Ranger, and the 1992–present Econoline van front frame sectioning procedures currently available from Ford Motor Company as an approved repair procedure. The sectioning procedure requires cutting off the front frame horn in front of the first crossmember. After removing the front frame horn, there is a ring-like section of the frame that has to be removed from inside of the remaining mid-rail. The new frame horn has a designed taper that inserts into the mid-rail to assist in alignment and welding. Ford Motor Company states that if there is evidence of damage behind the first crossmember (buckling, cracking, etc), the entire frame must be replaced. Magnesium Alloy Radiator Core Support The 2004 F-150 also has a new radiator core support. A bolt–on cast magnesium alloy part replaces the traditional welded-on steel design. This is only offered on F-150 models. Ford engineers considered using tubular steel, aluminum, and plastic before deciding on magnesium. The switch from steel to magnesium results in a weight savings of about 9 kg (20 lb). Magnesium is much lighter, stronger, and more resistant to corrosion than steel. On the downside, however, magnesium has the tendency to crack or break either from collision damage or during straightening due to its quick work-hardening characteristics. Magnesium is also not weldable with common collision repair facility GMA (MIG) welding capabilities. Do not use oxyacetylene equipment or plasma arc cutting equipment around this or any other magnesium part, for example to remove severely damaged parts. If magnesium catches on fire, it requires a class D fire extinguisher (see Figure 3). Do not use class A, B, or C fire extinguishers or water on a magnesium fire. A, B, or C fire extinguishers will spread the burning material around without extinguishing it. Water and molten magnesium will produce hydrogen gas and may cause an explosion. Other New Features
The 2004 Ford F-150 also has a new airbag system and is using a new type of steel construction called Quiet Steel™ on some parts. The dual stage airbag system on the F-150 uses an occupant classification sensor (OCS) on the passenger side. A separate Advantage Online article on these types of systems will be coming soon. Quiet Steel™ is being used on the dash panel and oil pan. Quiet Steel™ is an engineered plastic layer sandwiched between two cold rolled layers of steel. It is used to help lower sound levels and vibration. A separate Advantage Online article on this material is also coming soon. Conclusion When the new Ford F-150s start arriving in collision repair facilities, remember that there are some new design changes. There is a new repair option to the front frame rails, a cast magnesium radiator core support that has repair limitations as well as safety concerns, a new airbag system, and the use of Quiet Steel™. Keep these in mind to achieve a complete and safe repair for your customers. |
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