Front Side Member Section

Removal

1. WARNING: Before beginning any service procedure in this manual, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Body Repair Health and Safety and General Precautions (100-00 General Information, Description and Operation).
   

1. Remove the hood.
   

1. Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   

1. Rough straighten to dimensionally restore the vehicle to pre-accident condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. NOTICE: Due to the positions of the inner reinforcement(s), it is very important that the dimension provided is accurately met.

   NOTE: The cut shown is the final cut for the inner part.

   General Equipment : Air Body Saw

1. General Equipment : Spot Weld Drill Bit

1. NOTICE: Do not cut inner part or reinforcements of the side member.

   Separating cut through outer part of the front side member.
   General Equipment : Air Body Saw

Installation

1. General Equipment : Air Body Saw

1. General Equipment : Air Body Saw

1. General Equipment : Resistance Spotwelding Equipment
   General Equipment : MIG/MAG Welding Equipment

1. General Equipment : MIG/MAG Welding Equipment

1. General Equipment : MIG/MAG Welding Equipment

1. General Equipment : 8 mm Drill Bit
   General Equipment : MIG/MAG Welding Equipment

1. General Equipment : MIG/MAG Welding Equipment

1. General Equipment : MIG/MAG Welding Equipment

1. Metal finish the repair area using typical metal finishing techniques.
   

1. NOTE: Seam sealing must be restored to factory original condition.

   Refinish using a Ford approved paint system.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Refer to: Fender (501-02 Front End Body Panels, Removal and Installation).
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
   Refer to: Front Fog Lamp (417-01 Exterior Lighting, Removal and Installation).
   

1. Install and align the hood.
   Refer to: Hood Alignment (501-03 Body Closures, General Procedures).
   

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