Research Bulletin 2001-1

Frame Replacement on 1997-2001 Ford F-150 and F-250 Truck Models

Vehicles and Component Group Affected

Vehicles:	1997-2001 Ford F-150 and F-250 light duty (LD), Super Cab and Super Crew pickup trucks. This includes two- and four-wheel drive vehicles.
Component Group:	Frame

Description

BASED ON A RECENT CRASH TEST, REPLACEMENT OF THE FRONT PORTION OF THE FRAME ON THE ABOVE-REFERENCED VEHICLES SHOULD NOT BE ATTEMPTED OR AUTHORIZED. The crash test revealed that this particular procedure performed on the above-referenced vehicles (the removal and replacement of the front portion of the frame at the factory joint located approximately at the midpoint of the front door opening) could result in damage to the fuel tank when the vehicle is involved in a frontal impact crash.

Tech-Cor performed the above-described repair procedure on a 2000 Ford F-150 light duty (LD) pickup truck and a crash test of the repaired vehicle was conducted under the National Highway Traffic Safety Administration standards for testing under the New Car Assessment Program. The test consisted of a flat frontal barrier crash at 35.1 miles per hour (56.4 kph). As a result of this crash test, the fuel tank of the test vehicle incurred a puncture by contact with a bracket mounted on the underside of the cab. The puncture resulted in a significant amount of fuel system fluid spilling immediately after the test.

HENCE, AS MENTIONED ABOVE, REPLACEMENT OF THE FRONT PORTION OF THE FRAME ON THE ABOVE-REFERENCED VEHICLES SHOULD NOT BE ATTEMPTED OR AUTHORIZED.

The information provided in this bulletin is for educational purposes only. Although every effort has been made to ensure the accuracy of the information contained in this bulletin, Tech-Cor assumes no responsibility or liability for any repairs performed using information from any publication issued by Tech-Cor.

Any person performing repairs must determine whether any suggested or recommended procedures or repairs are suitable or appropriate for the particular vehicle being repaired. The repairer remains solely responsible for such determination, as well as for the proper completion of the repairs.

Reproduction of this bulletin is not permitted without the written approval of Tech-Cor.