Lincoln Navigator: Full Frame and Body Mounting / Front Bumper Bracket. Removal and Installation

Special Tool(s) / General Equipment

Removal

  WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if damaged. Prior to replacement of frame rail crush zones, straighten damaged frame rails to correct frame dimensions. Failure to follow these instructions may adversely affect frame rail crush zone performance and may result in serious personal injury to vehicle occupants in a crash.

NOTICE: Collision damage repair must conform to the instructions contained in this workshop manual. Replacement components must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint components) are not authorized by Ford.

NOTE: LH side shown, RH side similar.

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. Remove the front bumper.
      Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).
      
   2. Remove the wheel and tire.
      Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
      
   3. Unbolt the 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. Anchor the vehicle to a frame rack following the equipment manufacturer's instructions.

1. NOTE: Be careful not to cut into the frame horn, it will be reused.

   NOTE: LH side shown, RH side similar

   Grind the welds holding the front bumper bracket to the frame and remove the front bumper bracket.
   Use the General Equipment: Grinder

1. NOTE: LH side shown, RH side similar

   Clean the areas of the frame where the welds were ground.
   

Installation

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

1. Loosely clamp the replacement bracket in a preliminary position. Perform measurements to verify proper placement of the new front bumper bracket, then clamp firmly into position.
   
   • With all measurements verified and the new front bumper bracket in proper position, tack-weld the new front bumper bracket in place to the frame horn.
     Use the General Equipment: MIG/MAG Welding Equipment
     Use the General Equipment: Locking Pliers

1. Re-check measurements, then solid weld the front bumper bracket to the frame horn.
   Use the General Equipment: MIG/MAG Welding Equipment

1. Metal finish the repair area using typical metal finishing techniques.
   

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

1. Install the wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Install the front bumper.
   Refer to: Front Bumper (501-19 Bumpers, Removal and Installation).