Fulltext TSBs

Technical Service Bulletins

TSB
06-3-4
  • PICK UP BOX TO FRAME INTERFERENCE FOLLOWING FRAME REPLACEMENT – 133 INCH SUPERCAB AND 139 INCH SUPERCREW WHEELBASE VEHICLES W/5.5 FOOT BOX
Publication Date: January 26, 2006

FORD:
2004 F-150

ISSUE:

When replacing the frame on these vehicles, the following conditions may exist which require corrective action to ensure the box is mounted correctly to the new service frame.

  • Condition A – The front crossmember on the original box may interfere with the front outrigger bracket on the new service frame, not allowing the box to mount correctly. In addition, the under-mount attachment holes in the front box crossmember may no longer be in alignment with the opening(s) in the new service frame outrigger brackets
  • Condition B – The box rests correctly on the new service frame. However, the under-mount attachment holes on the front box crossmember are no longer in alignment with the opening(s) in the new service frame outrigger brackets

ACTION:

To correct this condition modify the outrigger bracket on new service frame to eliminate possible interference, refer to the following Service Procedure.

SERVICE PROCEDURE

Condition A:

  1. Using a cut-off wheel or related tool, remove the shaded portion of right and left Front Outrigger Bracket from the new service frame. This will remedy clearance issues between the box front crossmember and the frame outrigger brackets (Figure 1).


    Figure 1 – Article 06-3-4

  2. Lower the box into the frame.
  3. Position the box on the frame in correct alignment to the vehicle cab (side-to-side and fore-aft).
  4. Install the six (6) box to frame fasteners from the top down (through the inside of the box to the frame). Torque fasteners to 80 N-m (59 lb-ft).
  5. Lift vehicle on a hoist.
  6. Using a die-grinder or similar tool, elongate the bolt hole in the right and left frame outrigger brackets so new fasteners can be inserted. The box front crossmember bracket is equipped with weld nuts.
  7. Install two (2) new fasteners, Part Number W704971-S439, from the bottom through the front outrigger bracket into the box front crossmember bracket weld nuts. Torque to 40 N-m (30 lb-ft).

Condition B:

  1. Lower the box into the frame.
  2. Position the box on the frame in correct alignment to the vehicle cab (side-to-side and fore-aft).
  3. Install the six (6) box to frame fasteners from the top down (through the inside of the box to the frame). Torque fasteners to 80 N-m (59 lb-ft).
  4. Lift vehicle on a hoist.
  5. Using a die-grinder or similar tool, elongate the bolt hole in the right and left frame outrigger brackets so new fasteners can be inserted. The box front crossmember bracket are equipped with weld nuts.
  6. Install two (2) new fasteners, Part Number W704971-S439, from the bottom through the front outrigger bracket into the box front crossmember bracket weld nuts. Torque to 40 N-m (30 lb-ft).

PART NUMBERPART NAME
W704971-S439Fastener – (Requires 2)

WARRANTY STATUS:

Information Only – Not Warrantable


NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

Copyright 2006 Ford Motor Company