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First pic is looking at the back of the shock tower. See that nasty weld?Second pic is looking at the engine crossmember from just over the top of the TTB differential. See the nasty crack in that crossmember? I welded just the end of it for now, to get the rest of it I'd have to pull the TTB out, grind down that weld and run a fresh, continuous bead. Would love to use a fishplate or doubler plate of some sort, but the way it curves over the front differential I dunno if I could...A few folks over at F150forum say I should either replace the frame or get another truck.I personally have no idea what the best way to fix this is, if it's even repairable. It was suggested to me that the rest of the body may not truly be straight either.Any thoughts on this?
Also, note the other weld to the left of the second picture. That crossmember had been damaged pretty good, and welded even worse.

 

Honestly, I'd say its a parts truck now. You could drive it I guess so long as you checked the cracks daily for expansion

The shock tower one doesn't make much sense to me, isn't it riveted/bolted on? I see no reason for the weld to even be there.....

 

So is it the Frame that is cracked or the crossmember? I just can't seem to picture where what is...

 

The picture on the right is right directly behind the steering gear.

 

NOW I can picture it. It seems to be a common stress point. My cross member broke off RIGHT where its riveted to the frame. I took it to a local shop, here they repaired it and reinforced that area. $400 including a wheel alignment. That was pro welding.

From what I can see, it looks like someone previously re-welded the crossmember to the frame?

 

Yes, someone has re-welded that area. I took it on some trails last weekend, and although my front end is creaking and groaning (tie rods I think) the crack is not spreading, so I am planning on driving it for a lil while longer until I've got the funds to replace all 4 tires. At that point, I'll have the alignment done first and probably have the damage repaired also, then have the tires installed.

 

I would suggest that you stay off the trails, at least until you have that looked at by somebody that knows more about frames and frame repairs. It would suck to stranded out in the boonies.