Full Frame and Body Mounting: Other Ford Explorer IV

Drilling Precautions

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 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 hole is at least the specified distance above the frame centerline. The drilled hole is at least the specified distance from any other existing bracket or component of the frame.

Welding Precautions

Material

Note. Whenever factory E-coat has been removed by sanding, grinding or weld burn-off, the coating must be restored. Use low temperature anti-corrosion coating.

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. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) . Do not use gas welding equipment. Use a temperature-indicating crayon to make sure that the temperature does not exceed 750°C (1,400°F). Install new welded components by heliarc, stick or MIG welding where possible. If heliarc, stick or MIG welding is not possible, use puddle welding.

Frame Straightening

Material

1. When straightening the frame, make sure the following requirements are met: CAUTION: Reposition and/or shield any fuel lines, brake lines or wiring harness or component in the heated area. NOTE: Whenever factory E-coat has been removed by sanding, grinding or weld burn-off, the coating must be restored. Use low temperature anti-corrosion coating. If heat is needed to straighten a frame member, keep the temperature below 650°C (1,200°F) (a dull red glow). A temperature-sensitive thermal melt crayon should be used to monitor heat buildup. Heat should be kept to a minimum area so that the hardness of the metal will not be affected. Straightening should only be attempted on frames that fail to meet specifications of the diagonal checking method or where damage is apparent. Straightening should be limited to parts which are not severely bent. Reposition and/or shield any fuel lines, brake lines or wiring harnesses or components in the heated area.

Body Misalignment Check

1. To align or square a body, take 2 opposite diagonal measurements between pillars. Take measurements between reference points such as crease lines or weld joints that are diagonally opposite each other on the 2 pillars being measured.
2. When repairing a vehicle with damage on both the body and frame, take horizontal and vertical measurements from a vehicle of the same body style and transfer the dimensions to the damaged vehicle. Alignment can be made by diagonal measurements taken from points on the 2 pillars.

Scheme 14

Scheme 15

1. To align or square a body, take 2 opposite diagonal measurements between pillars. Take measurements between reference points such as crease lines or weld joints which are diagonally opposite each other on the 2 pillars being measured.
2. When repairing a vehicle with damage on both the body and frame, take horizontal and vertical measurements from an intact Explorer or Mountaineer vehicle and transfer the dimensions to the damaged vehicle. Alignment can be made by diagonal measurements taken from points on 2 pillars.
3. The dimensions of the underbody must be restored in repairing major body damage to provide correct front and rear wheel geometry. Once the frame and suspension members are aligned, other repair operations can be carried out.

Scheme 16

Body Support - Number 4

Note. Explorer/Mountaineer only.

Scheme 17

Transmission Support Crossmember

Note. Explorer/Mountaineer shown, Explorer Sport Trac similar.

Scheme 18