File 94 of 133
Prev | Next

tsb901309rearshockcracks.jpg | Hits: 4494 | Posted on: 4/20/09 | View original size (44.18 KB)

TSB 90-13-09 Rear Shock Cracks
(IF THE IMAGE IS TOO SMALL, click it.)
Publication Date: June 20, 1990

LIGHT TRUCK: 1987-90 F-150, F-250, F-350

ISSUE: The frame side rails may crack at the rear gas shock bracket rivet locations. The cracking appears on trucks that are continuously operated off-road.

ACTION: Install a frame reinforcement kit. Refer to the following procedure for service details.

SERVICE PROCEDURE
1. Remove the rear wheels and inspect the rear shock bracket areas for cracks or damage.
2. Disconnect the shock absorber from the upper and lower mounting points.
a. Check the frame to determine if a weld repair is adequate for the amount of damage sustained. (See Weld Repair Guide - Step #6a, for information).
b. Remove any fuel and brake lines in damaged area.
3. Remove the three (3) rivets holding the shock absorber bracket to the side rail.
a. Drill a 1/8" (3.175 mm) hole through the rivet.
b. Re-drill the same hole location with an 11/32" (8.731 mm) drill through shank.
c. Use an air-chisel to remove the head.
d. Drive out the rivet with a punch.
4. Clean the affected area with a wire brush.
5. Position the frame into its original location. Tack weld the frame rail to assist in holding its position.
6. Weld Repair Guide:
a. Locate the crack and clean the surface.
CAUTION: A CRACK WHICH HAS TRAVELED PAST THE MIDPOINT OF THE SIDERAIL BEND RADIUS SHOULD NOT BE WELDED. A NEW FRAME ASSEMBLY IS REQUIRED IN THIS CASE.
b. Drill a 3/16" (4.763 mm) hole at the end of the crack into the siderail.
c. Grind out a groove, top and bottom, 25% of the metal thickness deep along the crack.
d. Run a continuous weld along the groove.
* Direct the weld away from the hole.
* Weld both sides.
* Fill the end of the crack hole.
e. Grind all weld deposits flush with the siderail metal.
7. Place the reinforcement plate over the outside of the siderail.
8. Drill out the bolt holes from the inside out.
a. Use the shock bracket holes in the frame rail as a guide.
b. Line drill through the rail and plate with a 12 mm bit.
c. Drill the shock absorber bracket mounting holes to 12 mm.
9. Install the shock absorber bracket by using 12 mm fasteners and nuts.
a. Place the head to the outside, the nut to the inside of the rail.
b. Tighten the bolt to a torque of 88 lb.ft. (120 N-m).
10. Weld the reinforcement plate to the frame rail.
11. Paint repaired area after cooling.
12. Re-install the shock absorber.
13. Install the wheel and remove the truck from supports.

PART NUMBER PART NAME
E7TZ-5L005-A Frame Reinforcement Kit

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Basic Warranty Coverage

OPERATION DESCRIPTION TIME
901309 M Time

For other TSBs, check here.

See also:
. . . .