Crown Victoria V8-4.6L SOHC VIN 6 (1996)
On the inboard side of the frame rails, inspect that the main part of the bracket is welded up both sides and along the top. This weld rises about 2 inches
on the forward side, about 2-1/2 inches on the rearward side, and about 4-1/4 inches across the top of the bracket.
Area B:
On the outside of the frame rail toward the rear of the vehicle, inspect that the bracket ear has approximately 2 inches of weld.
Area C:
Also on the outside of the frame rail but toward the front of the vehicle, inspect that the bracket ear has approximately 2-1/2 inches total weld. This weld
should extend 1 inch on each side and 1/2 inch across.
b.
Additionally, perform the following operation. Use a 10" - 12" adjustable (Crescent) wrench, Vise-Grip, or Channel-Lock pliers to grab the
lower bracket attachment tabs (areas B and C) and apply 15 -20 lbs. of force on the end of the tool. Movement of the lower attachment tabs
relative to the frame rail indicates a possible cold weld and requires repair of the weld(s).
5.
Action:
a.
If the above inspection revealed no suspect welds or cracked brackets and did not exhibit the noise described above, lower the vehicle,
record vehicle VIN and date of inspection, and return to customer.
b.
If the above inspection revealed no suspect welds or cracked brackets but did exhibit the noise described above, perform normal diagnostics
to identify the source of the noise and service procedures as appropriate prior to returning vehicle to customer. Record vehicle VIN and date
of inspection, and return to customer.
c.
If inspection revealed suspect welds or cracked bracket (s), repair per instructions noted on Attachment III.
Bracket Repair Procedure - Areas "B" and "C" Only
* If inspection reveals the need for repairs other than in Areas "B" and "C", call 1-800-325-5621 for further direction. Mention Program 96B98 and be
prepared to describe the condition in detail.
NOTE:
Steps that apply to a particular side will be called out as such.
1.
Install Rotunda Memory Saver 014-R1064 or equivalent, then disconnect battery cables.
2.
Turn off air suspension if so equipped and raise vehicle on hoist.
3.
Turn front wheels to gain access to bracket. (Right or left side as necessary)
4.
Remove small locating clip and position plastic inner fender away from work area, if necessary. (Right or left side as necessary).
WARNING
TO AVOID PERSONAL INJURY, EYE AND EAR PROTECTION MUST BE WORN DURING GRINDING PROCEDURES.
Prepare affected area for welding by grinding away any paint or weld splatter, then recheck weld for cracks.
WARNING
POSITION A WELD SHIELD OVER THE FUEL, VAPOR AND BRAKE TUBES IN THE AREA TO BE WELDED. COVER THE SHIELD
WITH WET RAGS TO PROTECT IT FROM THE HEAT FROM THE WELDING PROCEDURE.
Fabricate and position a shield over the portion of the fuel, vapor and brake tubes nearest the bracket. Wrap wet rags around the shield to protect against
heat. (Right or left side as necessary).
CAUTION
Do not use Oxy-Acetylene torch to weld brackets or frame members. Excessive heat may weaken the metal in the frame members and cause
permanent damage.
CAUTION
As a precaution against damage to electrical components, be sure to disconnect the battery cables before using any welding equipment. Also it is
imperative to connect the ground clamp as close to the work area as possible. Perform all welding using Rotunda Mig Wire Feed Welder 066-00051
or equivalent using a 75/25 or 80/20 Argon/CO2 gas mix, and welding wire meeting AWS-E-70S specification. It is essential that the repair welds,
particularly on load bearing parts or parts contributing to the strength of the assembly, are equivalent to the original in size, type, and strength.
MIG weld affected area following all standard welding practices. Refer to the Inspection procedure to determine exact repair needs.
5.
Clean welds of all slag, then apply Super Seal Aerosol Anticorrosion Compound, F3AZ-19515-SA, or equivalent over the repaired area.
