Town Car V8-4.6L SOHC VIN W (1999)
6.
Unclip ABS sensor wire from frame and position aside. Refer to Figure 2.
7.
If equipped with air spring, wrap air spring in welding blanket.
8.
CAUTION:
If a crack is found, grind only enough metal away to form the V groove. Do not grind completely through frame parent metal. If frame is
cracked, grind a V groove in crack, then remove E coat from around crack. Mig weld the groove using standard mig welding procedures. See
Figure 2 for location of mig welder grounding clamp.
9.
CAUTION:
Only remove paint and any weld material that interferes with reinforcement plate fit. Do not grind frame parent metal. Prep the frame by removing
any paint in the affected area. Grind only the welds that will interfere with the reinforcement plate sitting flush to the frame (plate must not "rock").
After grinding, position the plate to check that it sits flush and if necessary, strike any weld with a punch and hammer to deflect the metal enough to
allow proper fit.
10.
NOTE:
Reinforcement plate is properly positioned when the entire access hole is covered and the rear edge is no more than 10 mm (approximately 3/8
in.) from the "lance" on the frame. If necessary, verify proper positioning by close inspection using a shop light. Refer to Figure 2. Position and
clamp reinforcement plate onto frame completely covering access hole.
11.
CAUTION:
Burn-through is not permitted. If any burn-through occurs, the hole must be filled. Using standard mig welding procedures, tack weld
reinforcement plate to frame on the two (2) outboard corners, then proceed to weld the perimeter of the reinforcement plate in sequence shown
in Figure 2.
12.
Remove weld blankets, if previously installed.
13.
Spray undercoating on plate and welds being careful to avoid any overspray.
14.
Reclip ABS sensor wire.
15.
Repeat steps 6 through 14 for other side.
