Frame - Rivet Replacement with Bolts Service Tip
Article No.97-4-7
02/17/97
FRAME - RIVET REPLACEMENT WITH BOLTS - SERVICE TIPS
LIGHT TRUCK:
1980-96 BRONCO
1980-97 ECONOLINE, F-150-350 SERIES
1983-97 RANGER
1984-90 BRONCO II
1986-97 AEROSTAR
1988-97 F SUPER DUTY, F-47
1991-97 EXPLORER
This TSB article is being republished in its entirety to include 1997 model year vehicles.
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.
SERVICE PROCEDURE
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.
1. Inspect for a loose or damaged rivet.
2. Remove any damaged or loose rivets.
a. Drill a 3.175 mm (1/8") hole through the rivet.
b. Redrill the same hole through the shank of the rivet.
^ Use an 8.731 mm (11/32") drill for 3/8" and 10 mm rivets.
^ Use a 9.525 mm (3/8") drill for 11.113 mm (7/16") rivets.
c. Remove the rivet head with an air chisel.
d. Drive out the rivet with a punch and hammer.
3. Line ream the hole to the replacement bolt nominal size with a hole tolerance of +/- 0.127 mm (0.005").
4. Free hole of burrs after reaming to allow bolt head and nut to seat properly.
5. Select the bolt length to have a minimum of two (2) threads protruding from outer face of nut. Refer to the following 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.
6. Check to be sure there is a 12.7 mm (1/2") minimum clearance of bolt to adjacent components, except engine and transmission, which must have at least 19.05 mm (3/4") clearance to allow for powertrain roll.
7. Tighten the bolts to the specifications shown in the Bolt Selection Chart.
NOTE:
GRADE 8 BOLTS MAY BE SUBSTITUTED FOR ANY APPLICATION.
Parts Block
OTHER APPLICABLE ARTICLES: 96-4-11
SUPERSEDES: 96-15-11
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-97 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles
OPERATION DESCRIPTION TIME
970407A Replace Rivet 0.5 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
5005 57
OASIS CODES: 304000, 305000, 390000