Attachment III - Technical Information

AFFECTED VEHICLE:
1998 AND 1999 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR (LIMO, LIVERY)

SERVICE PROCEDURE

1. Record radio stations.

2. Disconnect battery negative cable.

3. Raise vehicle on hoist and remove rear wheels.





4. Check to verify torque on both rear suspension upper arm pivot frame bolts is at minimum of 128 Nm (95 lb-ft). Refer to appropriate Service Repair Manual for proper bolt tightening procedure. Refer to Figure 1.

5. Cut off portion of RH flag nut's "flag" that protrudes from frame. See Figure 1.





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.

16. Install tires. Tighten lug nuts to 129 Nm (95 lb-ft). Lower hoist.

17. Connect battery negative cable.

18. Program radio stations.