Fulltext TSBs

Technical Service Bulletins

TSB
97-4-7
  • FRAME – RIVET REPLACEMENT WITH BOLTS – SERVICE TIPS
Publication Date: FEBRUARY 17, 1997

LIGHT TRUCK:
1980-1996 BRONCO
1980-1997 ECONOLINE, F-150-350 SERIES
1983-1997 RANGER
1984-1990 BRONCO II
1986-1997 AEROSTAR
1988-1997 F SUPER DUTY, F-47
1991-1997 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.
    1. Drill a 3.175mm (1/8″) hole through the rivet.
    2. Redrill the same hole through the shank of the rivet.
      • Use an 8.731mm (11/32″) drill for 3/8″ and 10mm rivets.
      • Use a 9.525mm (3/8″) drill for 11.113mm (7/16″) rivets.
    3. Remove the rivet head with an air chisel.
    4. 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 0.127mm (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 12.7mm (1/2″) minimum clearance of bolt to adjacent components, except engine and transmission, which must have at least 19.05mm (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.


    BOLT SELECTION CHART
    Rivet DiameterBolt SizeBolt Part NumberWasher Part NumberNut Part NumberTorque Specifications
    3/8″ and 10mm7/16″-14×1.25″56561-S2Not Required382400-S245-68 N-m (33-50 lb-ft)
    7/16″-14×1.75″56563-S2Not Required382400-S245-68 N-m (33-50 lb-ft)
    7/16″1/2″-13×1.5″ (Grade 5)56783-S100Not Required33773-S272-102 N-m (53-75 lb-ft)
    1/2″-13×2.0″ (Grade 8)383896-S244879-S233773-S2102-142 N-m (75-105 lb-ft)



PART NUMBERPART NAME
56561-S2Bolt (7/16″-14×1.25″)
56563-S2Bolt (7/16″-14×1.75″)
56783-S100Bolt (1/2″-13×1.5″)
383896-S2Bolt (1/2″-13×2.0″)
382400-S2Nut
33773-S2Nut
44879-S2Washer

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

OPERATIONDESCRIPTIONTIME
970407AReplace Rivet0.5 Hr.

DEALER CODING

BASIC PART NO.CONDITION CODE
500557

OASIS CODES:

304000, 305000, 390000