Rivet Replacement with Bolts
For other TSBs, check here.

TSB 97-4-7 FRAME - RIVET REPLACEMENT WITH BOLTS

Publication Date: FEBRUARY 17, 1997

LIGHT TRUCK:
1980-1996 BRONCO
1980-1997 ECONOLINE, F-150-350 SERIES
1983-1997 RANGER
1984-1990 BRONCO II
1986-1997 AEROSTAR
1988-1997 F SUPER DUTY, F-47
1991-1997 EXPLORER

ISSUE: Damaged or loose frame rivets should be replaced with approved service bolts. WELDING IS NOT ACCEPTABLE.

ACTION: If service is required, replace standard rivets with approved service bolts. Refer to the following Service Procedure for details.

NOTE: THE "HUCK" RIVET BETWEEN THE #1 CROSSMEMBER AND THE LH FRAME RAIL SHOULD BE SERVICED PER TSB 91-25-18. THIS PROCEDURE DOES NOT APPLY.

SERVICE PROCEDURE
Inspect for a loose or damaged rivet.
Remove any damaged or loose rivets.
1.) Drill a 3.175mm (1/8") hole through the rivet.
2.) Redrill the same hole through the shank of the rivet.
3.) Use an 8.731mm (11/32") drill for 3/8" and 10mm rivets.
4.) Use a 9.525mm (3/8") drill for 11.113mm (7/16") rivets.
5.) Remove the rivet head with an air chisel.
6.) Drive out the rivet with a punch and hammer.
7.) Line ream the hole to the replacement bolt nominal size with a hole tolerance of 0.127mm (0.005").
8.) Free hole of burrs after reaming to allow bolt head and nut to seat properly.
9.) Select the bolt length to have a minimum of two (2) threads protruding from outer face of nut. Refer to the Bolt Selection Chart for correct parts usage.

NOTE: IF A FLANGE HEAD NUT AND BOLT ARE NOT AVAILABLE, GRADE 5 HEX HEADS MAY BE SUBSTITUTED WITH ONE (1) FLATWASHER REQUIRED UNDER THE NUT AND ONE (1) FLATWASHER REQUIRED UNDER THE BOLT HEAD.
NOTE: GRADE 8 BOLTS MAY BE SUBSTITUTED FOR ANY APPLICATION.

Check to be sure there is a 12.7mm (1/2") minimum clearance of bolt to adjacent components, except engine and transmission, which must have at least 19.05mm (3/4") clearance to allow for powertrain roll.

10.) Tighten the bolts to the specifications shown in the Bolt Selection Chart.

See also:
. . .

Owner caption November 2005 · Photo 1052 of 5000