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Home >> Ford >> 2021 >> Bronco First Edition, 4D Utility >> Repair and Diagnosis >> Body & Frame >> Frames, Subframes & Crossmembers >> Full Frame And Body Mounting >> Removal And Installation >> Front Crossmember >> Installation

Front Crossmember: Installation

  1. Verify dimensional accuracy before performing any welding operations. Refer to: BODY DIMENSIONS AND BODY CONSTRUCTION .
  2. Sealer or adhesive must be applied with a minimum height of 6 mm. Refer to: SEALER, UNDERBODY PROTECTION MATERIAL AND ADHESIVES .
  3. Refer to: JOINING TECHNIQUES .

    Crossmember Type - I 

  4. Loosely clamp the replacement compatibility brackets in a preliminary position. Perform measurements to verify proper placement of the new bracket, then clamp firmly into position.

    • With all measurements verified and the new compatibility brackets in proper position, tack-weld in place to the frame assembly.

      Use the General Equipment: MIG/MAG Welding Equipment

      Use the General Equipment: Locking Pliers

    GFD628835Courtesy of FORD MOTOR COMPANY
  5. Perform final measurements, then solid weld the compatibility brackets.

    1. Weld length - 53mm Use the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 32mm
    3. Weld length - 33mm

    GFD628836Courtesy of FORD MOTOR COMPANY
    1. Weld length - 31mm Use the General Equipment: MIG/MAG Welding Equipment
    GFD629237Courtesy of FORD MOTOR COMPANY
  7. Loosely clamp the replacement crossmember in a preliminary position. Perform measurements to verify proper placement of the new front crossmember, then clamp firmly into position.

    • With all measurements verified and the new front crossmember in proper position, tack-weld in place to the frame assembly.

      Use the General Equipment: MIG/MAG Welding Equipment

      Use the General Equipment: Locking Pliers

    GFD628838Courtesy of FORD MOTOR COMPANY
  8. NOTE: Left hand (LH) shown in illustration, right hand (RH) similar.
    GFD629238Courtesy of FORD MOTOR COMPANY
  9. NOTE: Left hand (LH) shown in illustration, right hand (RH) similar.

    Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joint completely if this alignment is correct.

    1. Weld length - 81mm Use the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 82mm

    GFD628840Courtesy of FORD MOTOR COMPANY
  10. NOTE: The bracket is supplied without the lower control arm mounting holes present. It is intended that the required holes be added to the bracket after the bracket is installed to the frame cross member and proper measurements have been made to properly position the required holes on the bracket.

    Mark out the desired position for the lower control arm mounting bolts and drill a 16.5mm hole either side of the pocket clevis to allow the lower control arm bolts to pass through.

    • A horizontal slot like the replaced part may be required to allow for wheel alignment adjustment in the cross/car direction. Use the General Equipment: 15 mm Drill Bit

    • The nominal lower control arm bolt position should be at Y = 74mm and Z = 54mm from the steering gear mounting hole, center to center. This position may need to be adjusted dependent on vehicle wheel alignment.

    • De-burr all drilled holes and ensure surface for mounting lower control arm is clean and flat. Ensure all edges are rounded, do not leave sharp corners or edges.

    GFD628841Courtesy of FORD MOTOR COMPANY

    Crossmember Type - II 

  11. Loosely clamp the replacement bracket in a preliminary position. Perform measurements to verify proper placement of the new bracket, then clamp firmly into position.

    • With all measurements verified and the new front driveline axle bracket in proper position, tack-weld in place to the frame assembly.

      Use the General Equipment: MIG/MAG Welding Equipment

      Use the General Equipment: Locking Pliers

    GFD628842Courtesy of FORD MOTOR COMPANY
  12. Perform final measurements, then solid weld the Front driveline bracket.

    1. Weld length - 34mm Use the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 43mm
    3. Weld length - 31mm

    GFD628843Courtesy of FORD MOTOR COMPANY
  13. Loosely clamp the replacement crossmember in a preliminary position. Perform measurements to verify proper placement of the new front crossmember, then clamp firmly into position.

    • With all measurements verified and the new front crossmember in proper position, tack-weld in place to the frame assembly. Use the General Equipment: MIG/MAG Welding Equipment

    GFD629239Courtesy of FORD MOTOR COMPANY
  14. Re-check the frame replacement alignment by lowering the body, and then raise it. Weld the joint completely if this alignment is correct.

    1. Weld length - 81mm Use the General Equipment: MIG/MAG Welding Equipment
    2. Weld length - 82mm

    GFD628845Courtesy of FORD MOTOR COMPANY

    All vehicles 

  15. Metal finish the repair area using typical metal finishing techniques.
  16. Refinish using a Ford approved paint system. Refer to: PAINTWORK DEFECTS AND DAMAGE .
  17. Restore corrosion protection. Refer to: CORROSION PREVENTION .
  18. Sealing work: All areas must be sealed to production level. Refer to: SEALER, UNDERBODY PROTECTION MATERIAL AND ADHESIVES .
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