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So while investigating a creaking noise under my 1995 F150, I discovered a crack in the engine frame cross member. It's on the drivers side, right behind the steering box. The crack is about 3-4 inches long. I'm confident my frame repair guy can fix it, I'm just wondering how many have dealt with this, I know it's a fairly common problem with these trucks. I attached the best pictures I could get of it.
Yes this is an issue I've seen addressed here on the forum a couple times.. A lot of people have a good welder box this in to reinforce this particular area but It doesn't look like a fun job that's for sure.
I've heard of it, but usually only 4wd and guys with bigger tires. The flex from the steering box works the frame and cracks it.
I don't see an issue with fixing it. Clean it up, grind a "V" and weld it. Big problem is getting to it. Maybe a fish plate over it to help from repeating.
When my '93 came off warranty I lifted it and installed tire w/ a very little backspacing.
I pulled the steering box out of the frame twice, the first time within 10k miles of lifting it.
Had a body shop open up the frame and added gussets inside behind the steering box, but never did any plating on the outside.
It has been years since having another problem with this, but it may be because I learned that you MUST be moving before turning the wheels and try to avoid sharp sudden turns.
Looks like you have a lot of rust too, so this might be a big project.
When my '93 came off warranty I lifted it and installed tire w/ a very little backspacing.
I pulled the steering box out of the frame twice, the first time within 10k miles of lifting it.
Had a body shop open up the frame and added gussets inside behind the steering box, but never did any plating on the outside.
It has been years since having another problem with this, but it may be because I learned that you MUST be moving before turning the wheels and try to avoid sharp sudden turns.
Looks like you have a lot of rust too, so this might be a big project.
I have a local frame shop that does frame rust and crack repair day in and day out. I'm very confident they will be able to fix this without much trouble.
That rust is just surface rust. I just got through restoring this truck. Here's a link- https://www.ford-trucks.com/forums/1519227-my-1995-f150-project-before-and-after-picture-heavy.html
Originally Posted by Freightrain
I've heard of it, but usually only 4wd and guys with bigger tires. The flex from the steering box works the frame and cracks it.
I don't see an issue with fixing it. Clean it up, grind a "V" and weld it. Big problem is getting to it. Maybe a fish plate over it to help from repeating.
I don't have any lift, and my tires have never been bigger than 31s. Access to it is a little tight, but they should be able to get a mig in there to weld it up and plate it if necessary. Again I'm gonna have a frame shop repair it.
Mine cracked there in a similar fashion and the previous owner welded some tin foil or something over it. Seriously, it was like 1/16" thick plating so of course it cracked again. Didn't notice til after I bought it but all I did was cut out the crappy stuff, welded it back up and reinforced it with a piece of solid bar stock. Not the right way to fix it but it survived the first test (crossing a ditch at a 45 degree angle several times) and lasted thru many off road adventures, mudding, winching, pulling other trucks out and everything else right up until the day I parted her out.
A frame shop should be able to make that even tougher than it was when new.
I've heard they don't tend to crack if they do, and wondering if there's any truth to it. My truck has a front sway, and hefty front hitch that really ties the frame rails together. It's been 2 and 3 wheeling many times with 33" tires, and no cracks with 270k miles. Just gathering data for my own curiosity on the topic.
Mine had a front sway bar, for whatever that's worth. Although I later removed it to let the TTB suspension flex better off road. And your mention of the trailer hitch brings up a good point too. About a year after I welded the crack, I installed a winch using a 1/4" thick section of structural C-channel across the frame rails. I'm sure that did a lot to help reduce stress in that area. But that whole first year or so I was just as hard on it and it didn't break even before the winch.
I've heard they don't tend to crack if they do, and wondering if there's any truth to it. My truck has a front sway, and hefty front hitch that really ties the frame rails together. It's been 2 and 3 wheeling many times with 33" tires, and no cracks with 270k miles. Just gathering data for my own curiosity on the topic.
Interesting, I was wondering if a sway bar might have any effect on this or not. My truck does not have a sway bar, and as far as I can tell it never did.
Originally Posted by dixie460
Mine had a front sway bar, for whatever that's worth. Although I later removed it to let the TTB suspension flex better off road. And your mention of the trailer hitch brings up a good point too. About a year after I welded the crack, I installed a winch using a 1/4" thick section of structural C-channel across the frame rails. I'm sure that did a lot to help reduce stress in that area. But that whole first year or so I was just as hard on it and it didn't break even before the winch.
Thanks for the replies, I'm glad to hear your repaired frame has held up. I was thinking about adding a front hitch reciever once this is repaired to help stiffen things up.
Most of the diesel trucks that we had to fix in the same area did have anti-sway bars. As did many (most?) of the Broncos/F150's that we worked on.
In the case of the lighter trucks, most were lifted, but in the case of the heavier duty trucks, only about half were lifted, used larger tires, or were otherwise modified.
So at least in some cases having the anti-sway bar does not seem to be a guarantee of no cracks.
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