Body Panel System - Full Frame and Body Mounting Ford Cutaway E350

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The frame is made up of 2 steel channel rails and riveted crossmembers, except for the transmission support crossmember and engine support crossmember which are bolted. Vehicle application determines the crossmembers used.

The vehicle body sits on rubber body supports. There are lower and upper body supports to keep the vehicle body from sitting directly on the frame.

Rivet Removal

Note. Rivets that are removed will be replaced with the next larger size bolts.

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1. Drill a 1/8-inch pilot hole through the rivet.
2. Drill an 11/32-inch hole through the rivet (3/8-inch and 10-mm rivets), or drill a 3/8-inch hole through the center of 7/16-inch rivets.
3. Remove the rivet head.
4. Drive out the rivet with a punch.
5. Remove the support.

Rivet Replacement

Note. Rivets that are removed will be replaced with the next larger size bolts.

1. Drill a bolt hole in the support and the frame. Line drill a hole the size of the bolt through the old rivet hole (i.e., for 7/16-inch diameter rivets, use a 1/2-inch drill, 3/8-inch or 10-mm rivets use a 7/16-inch drill). Position the support. Insert the bolts, nuts and washers (Property Class 9.8 metric [Grade 8]) in the drilled holes (at least two threads on the bolt must protrude through the components). Tighten the bolts.

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1. If a hole must be drilled in the frame, make sure the hole meets the following requirements: The hole is at least the specified distance from bend radius. The edge of the drilled hole is at least the specified distance from the edge of the nearest hole. The edge of the drilled hole is at least the specified distance from the edge of the flange. The drilled hole is at least the specified distance from any other existing bracket or component of the frame.

Welding Precautions

1. If welding must be done on a frame, make sure the following requirements are met: If the frame is attached to the vehicle, the battery ground cable must be disconnected before using any electrical welding equipment. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) for correct battery disconnect procedures. Do not use gas welding equipment. Arc welding is the only approved method. Use a temperature-indicating crayon to make sure that the temperature does not exceed 750°C (1400°F). Replace spot-welded components by spot welding where possible. If spot welding is not possible, use puddle welding.

Frame Straightening

1. When straightening the frame, make sure the following requirements are met: If heat is needed to straighten a frame member, keep the temperature below 650°C (1200°F) (a dull red glow). Heat must be kept to a minimum area so that the hardness of the metal will not be affected. Straightening must only be attempted on frames that fail to meet specifications of the diagonal checking method or where damage is apparent. Straightening must be limited to parts which are not severely bent.

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1. After a bent frame member has been straightened, inspect the frame member closely for cracks. If any cracks are located, the damage must be welded and, if necessary, reinforced.
2. The following procedure details the recommended frame crack repair procedure: Stop drill the crack(s) at the end. V-grind the crack(s) in preparation for welding. Weld the crack(s). Grind off the weld excess. Add a reinforcing plate if necessary. The reinforcing plate must be made from flat or angle stock of the same material and thickness as the frame member being reinforced, and must extend to either side of the crack. Ideally, the reinforcement will be cut from the corresponding area of a similar frame. Weld the reinforcing plate entirely, using the skip weld method to reduce potential heat buildup from concentrating in any one particular area during repair.

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1. Secure the high-lift transmission jack to the transmission.
2. Disconnect the wiring harness from the crossmember, if equipped.
3. Remove the rear transmission mount insulator nuts.
4. Remove the heat shield-to-crossmember bolts.
5. Remove the RH crossmember nuts.
6. Remove the LH crossmember nuts.
7. Remove the LH crossmember bracket.
8. Remove the RH crossmember bracket and transmission support crossmember.
9. To install, reverse the removal procedure.

Scheme 17

1. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the side impact reinforcement (5Z011 left side, 5N100 right side). Remove the eight nuts (W520114-S426). Remove the side impact reinforcement.
3. To install, reverse the removal procedure.

Scheme 18

1. Raise and support the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the fuel tank protection bracket (9K037). Remove the bolt (W506435-S426). Remove the fuel tank protection bracket.
3. To install, reverse the removal procedure.

See also:
• BATTERY, MOUNTING AND CABLES
• JACKING & LIFTING