Lincoln Navigator: Full Frame and Body Mounting / Frame Members-Rear Frame Section. Removal and Installation

Special Tool(s) / General Equipment

Removal

1. Restore the vehicle to manufacturer's dimensions.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Remove the following items:
   1. Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).
      
   2. As equipped.
      Refer to: Muffler and Tailpipe (309-00 Exhaust System - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
      
   3. As equipped.
      Refer to: Fuel Tank Filler Pipe (310-01 Fuel Tank and Lines - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
      
   4. Refer to: Shock Absorber and Spring Assembly (204-02 Rear Suspension, Removal and Installation).
      
   5. Remove the spare wheel.
      Refer to: Frame and Body Mounting (502-02 Full Frame and Body Mounting, Description and Operation).
      
   6. Unbolt the Front End Sheet Metal (FESM) body mount bolts and raise or remove the body if required.
      Refer to: Frame and Body Mounting (502-02 Full Frame and Body Mounting, Description and Operation).
      

1. Rear frame section overview.
   

1. Position the vehicle on a frame rack and anchor per manufacturer's instructions.
   

1. NOTICE: Do not cut directly along the center of the weld line. Leave enough material on the front side of the weld centerline to allow the remaining weld and frame material to be ground back to the front edge of the front mid rail. This is necessary to make sure of correct fit between the frame and the replacement frame section.

   NOTE: Use caution not cut into the mid rear side rail as it will be reused.

   Using a plasma cutter, reciprocating saw or die-grinder, remove the damaged rear frame section.
   
   • Separate the ground area of the joints using an air chisel or similar tool and remove the complete rear frame section.
     Use the General Equipment: Grinder

1. NOTICE: Do not thin out the frame rail. The material must maintain a minimum thickness of 3.1 mm (0.12 in) after grinding. This is required to maintain correct energy management in the event of a collision.

   Grind off the excess welding material that remains in rear of the weld line on the frame mid-rail.

Installation

1. Refer to: Joining Techniques (501-25 Body Repairs - General Information, General Procedures).
   

1. NOTE: Verify dimensional accuracy before performing any welding operations.

   Install the new rear frame section into the mid rear section of the frame and tack weld the frame rails.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Perform a final measurement, then final weld the new rear section to the mid rear section on all overlap joints on both sides.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish the joint area typical metal finishing techniques.
   

1. Metal finish the joint area typical metal finishing techniques.
   

1. Refinish using a Ford approved paint system.
   

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

1. NOTICE: To avoid damage to the spare tire winch when installing the spare tire, DO NOT exceed 200 RPM if using power tool equipment.

   Install the following items:
   1. As equipped.
      Refer to: Fuel Tank Filler Pipe (310-01 Fuel Tank and Lines - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
      
   2. As equipped.
      Refer to: Muffler and Tailpipe (309-00 Exhaust System - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
      
   3. Refer to: Shock Absorber and Spring Assembly (204-02 Rear Suspension, Removal and Installation).
      
   4. Refer to: Rear Bumper (501-19 Bumpers, Removal and Installation).