S ervice E ngineering O perations Frame/Rail Sectioning kits and Serviceability- Review and Update Gerry Bonanni Ford Motor Company

S ervice E ngineering O perations 2 Benefits of Frame/Rail Sectioning Kits Ford Motor Company offers a wide variety of frame/rail sectioning kits, for both full frame and unibody vehicles. Their benefits include:  Lower cost repair solutions  Lower incidence of totaled vehicles  Increased body shop business and profits  Ensures a proper repair is performed, within factory guidelines

S ervice E ngineering O perations 3 Frame Sectioning Kits - Release Process The kits are developed within Ford following the points below:  Business case is developed using Industry collision data to identify and quantify the opportunity.  As part of the process, BSMAC panel members and other collision industry people are surveyed to quantify interest.  The team also works closely with Engineering to develop a feasible repair.

S ervice E ngineering O perations 4 Frame Sectioning Kits - Release Process To continue, other elements of the release process are:  Each kit is reviewed with the FCSD damageability team, and a repair trial may be performed to validate repair procedures and ensure quality of repair.  The output of this step is the final draft of kit repair instructions.  A full set of vehicle durability tests are run to validate the repair robustness when necessary.  Final release of the part takes place with the FCSD Parts and Service Logistics team

S ervice E ngineering O perations 5 Recent Structural Repair Efforts  The Focus front rail sectioning procedure has been released  Allows replacement of forward 12 inches of front frame rails.  Is available in the workshop manual Section

S ervice E ngineering O perations 6 Recent Structural Repair Efforts  A new front rail sectioning procedure for the Fusion/Milan/MKZ has been released  Allows replacement of forward section of front frame rails.  Is available in the workshop manual Section

S ervice E ngineering O perations 7 Recent Structural Repair Efforts  There is also a new rear rail sectioning procedure for the Fusion/Milan/MKZ has been released  Allows replacement of rearmost section of the rear frame rails.  Is available in the workshop manual Section

S ervice E ngineering O perations 8 Recent Structural Repair Efforts  The Focus front rail sectioning procedure has been released  Allows replacement of forward 12 inches of front frame rails.  Is available in the workshop manual Section

S ervice E ngineering O perations 9 Recent Structural Repair Efforts  Alternative sectioning location options for the 500, Montego, and Freestyle vehicles have been developed and released  Allows for 3 cut location options of front frame rails  Option 1 is 155 mm from front  Option 2 is 330 mm from front

S ervice E ngineering O perations 10 Recent Structural Repair Efforts  Alternative sectioning location options for the 500, Montego, and Freestyle vehicles have been developed and released  Option 3 is 870 mm from front

S ervice E ngineering O perations 11 Recent Structural Repair Efforts  The F-150 front and rear frame sections have passed durability testing and have been released  Allows replacement of the front or rear frame sections at the factory joints.  Technical procedures are available in the workshop manual section , or the included instruction sheet.

S ervice E ngineering O perations 12 Recent Structural Repair Efforts  Frame sectioning kits for the 2009 F-150 are currently being released  These will be ready for release when the vehicle launches/OK to buy date.

S ervice E ngineering O perations 13 Discussion Gerry Bonanni Body and Paint Damageability (734)