Service Engineering Operations FrameRail Sectioning kits and Serviceability

Service Engineering Operations Frame/Rail Sectioning kits and Serviceability- Review and Update Gerry Bonanni Ford Motor Company

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: ØLower cost repair solutions ØLower incidence of totaled vehicles ØIncreased body shop business and profits ØEnsures a proper repair is performed, within factory guidelines Service Engineering Operations 2

Frame Sectioning Kits - Release Process The kits are developed within Ford following the points below: ØBusiness case is developed using Industry collision data to identify and quantify the opportunity. ØAs part of the process, BSMAC panel members and other collision industry people are surveyed to quantify interest. ØThe team also works closely with Engineering to develop a feasible repair. Service Engineering Operations 3

Frame Sectioning Kits - Release Process To continue, other elements of the release process are: Ø 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. Ø The output of this step is the final draft of kit repair instructions. Ø A full set of vehicle durability tests are run to validate the repair robustness when necessary. Ø Final release of the part takes place with the FCSD Parts and Service Logistics team Service Engineering Operations 4

Recent Structural Repair Efforts Ø The Focus front rail sectioning procedure has been released Ø Allows replacement of forward 12 inches of front frame rails. Ø Is available in the workshop manual Section 501 -35 Service Engineering Operations 5

Recent Structural Repair Efforts Ø A new front rail sectioning procedure for the Fusion/Milan/MKZ has been released Ø Allows replacement of forward section of front frame rails. Ø Is available in the workshop manual Section 501 -35 Service Engineering Operations 6

Recent Structural Repair Efforts Ø There is also a new rear rail sectioning procedure for the Fusion/Milan/MKZ has been released Ø Allows replacement of rearmost section of the rear frame rails. Ø Is available in the workshop manual Section 501 -35 Service Engineering Operations 7

Recent Structural Repair Efforts Ø The Focus front rail sectioning procedure has been released Ø Allows replacement of forward 12 inches of front frame rails. Ø Is available in the workshop manual Section 501 -35 Service Engineering Operations 8

Recent Structural Repair Efforts Ø Alternative sectioning location options for the 500, Montego, and Freestyle vehicles have been developed and released Ø Allows for 3 cut location options of front frame rails Ø Option 1 is 155 mm front Ø Option 2 is 330 mm front Service Engineering Operations 9

Recent Structural Repair Efforts Ø Alternative sectioning location options for the 500, Montego, and Freestyle vehicles have been developed and released Ø Option 3 is 870 mm front Service Engineering Operations 10

Recent Structural Repair Efforts Ø The 2004 -2008 F-150 front and rear frame sections have passed durability testing and have been released Ø Allows replacement of the front or rear frame sections at the factory joints. Ø Technical procedures are available in the workshop manual section 501 -35, or the included instruction sheet. Service Engineering Operations 11

Recent Structural Repair Efforts Ø Frame sectioning kits for the 2009 F-150 are currently being released Ø These will be ready for release when the vehicle launches/OK to buy date. Service Engineering Operations 12

Discussion Gerry Bonanni Body and Paint Damageability (734)487 -6506 gbonanni@ford. com Service Engineering Operations 13