Broken frame
Thread Starter
|
Tuned
Joined: Feb 2022
Posts: 301
Likes: 30
From: Perth Ontario
Broken frame
I have a 1996 f150 4x4 reg cab long box. It's been oiled every year. The frame broke on driver's side right at the by the steering box. If any one is around the Perth Ontario area and has a good frame for the driver's side please let me know. I just can't belive it broke. The truck is in way too good of shape to not fix. Anything from 92 to 96..
Tuned
Joined: Jan 2015
Posts: 468
Likes: 90
You can also use a 4x2 frame, but will need to do some drilling to remove the 4x2 suspension/axles and replace them with yours. I tried HSS and carbide bits on the rivets and found that the gold bits from Home Depot (Dewalt?) worked best. Grind the tops flat on those you can reach to make for less drilling. Start with a small drill bit and work your way up. Drill to frame depth then use a sledge and punch to knock the rivet out. Make the frame/bracket holes 1/2" to fit the size-that's-easy-to-obtain Grade 8 replacement bolts and flange nuts. You might consider welding some extra material in the place where it cracked on the new frame. You don't want to go through this again.
FTE Legend
Joined: Jun 2006
Posts: 31,930
Likes: 1,499
From: Ottawa, Ontario
A cracked frame at the steering box isn't uncommon, so much so you may not have much luck finding a good replacement section from a donor. The solution is to weld and reinforce what you have.
Fleet Owner
Joined: Jul 2006
Posts: 20,326
Likes: 792
From: Mi'kma'ki
I didn't realize this was so common on the F150's. This means if a guy were wise, he would get himself a metal plate to fit and re-enforce his good frame, drill some steering box bolt holes in it, and get some longer bolts, to prevent the issue? Or has someone even wiser already put together, said stuff and sells it as a "kit"?...... If not, a guy might make himself a buck or two doing so? Just some thoughts.
Is there a clear enough spot to bolt in a plate though, or no?
Long live the 9th gen F-series!
Is there a clear enough spot to bolt in a plate though, or no?
Long live the 9th gen F-series!
Cargo Master
Joined: Mar 2010
Posts: 3,320
Likes: 287
From: Laramie, WY
Does this truck have a front sway bar? Seems like the trucks that break here lack the front sway bar cross member or something else that acts as a cross member forward of the steering gear (like a winch bumper).
Lead Driver
Joined: May 2011
Posts: 5,771
Likes: 441
I have performed many frame repairs on these for the steering box as well as the engine crossmember (often times both are torn/broken). It's relatively easy to fix if you are a competent welder, and relatively easy to fix if you aren't a welder but find a competent one. The key is to reinforce the area....which will mean pulling everything out of the way in order to get the welder all around the damaged area.
Thread Starter
|
Tuned
Joined: Feb 2022
Posts: 301
Likes: 30
From: Perth Ontario
Trending Topics
Lead Driver
Joined: May 2011
Posts: 5,771
Likes: 441
That's pretty rusty lol. What does the frame look like where it meets the cab at the firewall? How does the crossmember look?
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
10 Best Ford Truck Engines We Miss the Most!
Joe Kucinski
2026 Shelby F-150 Off-Road: Better Than a Raptor R?
Brett Foote
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!
Michael S. Palmer
10 Most Surprising 2026 Ford Truck Features!
Joe Kucinski
Top 10 Ford Trucks Coming to Mecum Indy 2026
Brett Foote
5 Best / 5 Worst Ford Truck Wheels of All Time
Joe Kucinski
Ford Super Duty: 5 Things Owners LOVE, 5 Things They LOATHE!
Joe Kucinski
Every 2026 Ford Truck Engine RANKED from WORST to FIRST!
Michael S. Palmer
The Best F-150 Deal of Every Trim Level (XL through Raptor)
Joe Kucinski
Cargo Master
Joined: Mar 2010
Posts: 3,320
Likes: 287
From: Laramie, WY
That is wrecked by rot and not simple metal fatigue. What's the rest of the frame look like? They're supposed to be 3/16" thick steel throughout on an F150. Rear spring hangers are potentially near snapping off. Is the body decent?
I agree that this truck is unsafe and should not be on the road until frame is replaced or repaired (if that's even feasible/worthwhile).
No fun to deal with! Sorry for your trouble.
I agree that this truck is unsafe and should not be on the road until frame is replaced or repaired (if that's even feasible/worthwhile).
No fun to deal with! Sorry for your trouble.
FTE Legend
Joined: Nov 2015
Posts: 30,832
Likes: 4,097
From: Angier, NC
I am with the others that is rust damage with maybe a little frame flex.
Check the rear of the frame from the rear axle back for rust and the shock mounts.
I never heard of trucks that dont have sway bars crack the frames but trucks that have large tires do crack the frames more then smaller tire ones.
I thought someone made a bracket / brace to fix cracked frames maybe JBGY?
If you do a frame swap try and get the paper work / BoS for the frame as it will have a VIN and if someone goes looking like DMV and see a different number on the frame from the door or the windshield you could be in a world of hurt.
Maybe check with the DMV before buying a frame?
Dave ----
Check the rear of the frame from the rear axle back for rust and the shock mounts.
I never heard of trucks that dont have sway bars crack the frames but trucks that have large tires do crack the frames more then smaller tire ones.
I thought someone made a bracket / brace to fix cracked frames maybe JBGY?
If you do a frame swap try and get the paper work / BoS for the frame as it will have a VIN and if someone goes looking like DMV and see a different number on the frame from the door or the windshield you could be in a world of hurt.
Maybe check with the DMV before buying a frame?
Dave ----
Fleet Owner
Joined: Jul 2006
Posts: 20,326
Likes: 792
From: Mi'kma'ki
Holy smokes. She rotted out before she cracked. If the rest of the frame is good, it's worth sourcing that front section and replacing it though. If not, you'll have to look the truck over and decide if it's worth a frame swap. I found a super clean 2wd frame for my 4wd. I only needed the back end of it. Very much unlike yours, mine is still grade A up front. Now A+ out back haha. Got it locally for $500. They're out there! These trucks are worth anything imo since new trucks are insanely priced now. There's no amount of $ that can be deemed as "too much" and "no longer worth it" anymore. Find what you need and do it. Even if it's a whole frame swap.
Thread Starter
|
Tuned
Joined: Feb 2022
Posts: 301
Likes: 30
From: Perth Ontario
That is wrecked by rot and not simple metal fatigue. What's the rest of the frame look like? They're supposed to be 3/16" thick steel throughout on an F150. Rear spring hangers are potentially near snapping off. Is the body decent?
I agree that this truck is unsafe and should not be on the road until frame is replaced or repaired (if that's even feasible/worthwhile).
No fun to deal with! Sorry for your trouble.
I agree that this truck is unsafe and should not be on the road until frame is replaced or repaired (if that's even feasible/worthwhile).
No fun to deal with! Sorry for your trouble.
Thread Starter
|
Tuned
Joined: Feb 2022
Posts: 301
Likes: 30
From: Perth Ontario
I am with the others that is rust damage with maybe a little frame flex.
Check the rear of the frame from the rear axle back for rust and the shock mounts.
I never heard of trucks that dont have sway bars crack the frames but trucks that have large tires do crack the frames more then smaller tire ones.
I thought someone made a bracket / brace to fix cracked frames maybe JBGY?
If you do a frame swap try and get the paper work / BoS for the frame as it will have a VIN and if someone goes looking like DMV and see a different number on the frame from the door or the windshield you could be in a world of hurt.
Maybe check with the DMV before buying a frame?
Dave ----
Check the rear of the frame from the rear axle back for rust and the shock mounts.
I never heard of trucks that dont have sway bars crack the frames but trucks that have large tires do crack the frames more then smaller tire ones.
I thought someone made a bracket / brace to fix cracked frames maybe JBGY?
If you do a frame swap try and get the paper work / BoS for the frame as it will have a VIN and if someone goes looking like DMV and see a different number on the frame from the door or the windshield you could be in a world of hurt.
Maybe check with the DMV before buying a frame?
Dave ----
Thread Starter
|
Tuned
Joined: Feb 2022
Posts: 301
Likes: 30
From: Perth Ontario
there is so much new parts on this truck . Only rust on body is a wheel arch . Which is what it was being taken out for and some exhaust work.
About 20 times a yr someone is asking to buy it . People stop at my house.
About 20 times a yr someone is asking to buy it . People stop at my house.