item description specification flushness specification 1 ...warning: collision damage repair must...
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GENERAL PROCEDURES: FRAME REP...DESCRIPTION AND OPERATION: BODY DIAGRAMS (BODY REPAIRS)50135 Body Repairs 2013 F250, 350, 450, 550 Super DutyDESCRIPTION AND OPERATION Procedure revision date: 07/16/2013
Body
WARNING: Collision damage repair must conform to the instructions contained in this workshop manual. Replacementcomponents must be new, genuine Ford Motor Company parts. Recycled, salvaged, aftermarket or reconditioned parts(including body parts, wheels or safety restraint components) are not authorized by Ford.
Departure from the instructions provided in this manual, including alternate repair methods or the use of substitute components, riskscompromising crash safety. Failure to follow these instructions may adversely affect structural integrity and crash safety performance,which could result in serious personal injury to vehicle occupants in a crash.
The body consists of the following:
Body on frame design, front frame section constructed of hydroformed railsCabforward designUnique front structure constructed of hydroformed, HighStrength Low Alloy (HSLA) 350 steel railsApillar and cowl side structure integrated with new front structure railsMagnesium upper radiator supportHSLAsteel lower radiator supportLightweight steel welded panel constructionBolted, removable front fenders, hinged doors, tailgate and hoodA standard 2door regular cab or optional 4door SuperCab and 4door Crew CabStandard 1.98 m (6.5 ft) or optional 2.44 m (8 ft) pickup bed length2.44 m (8 ft) and 1.98 m (6.5 ft) pickup beds available with optional Dual Rear Wheels (DRW) configurationDRWpickup box fender flair constructed of polyurethane Reinforced Reaction InjectionMold Material (RRIM)Hood and front fenders constructed of dent resistant highstrength steelF250/450 pickup(s) available with the following wheelbase lengths. Pickups are configured on wide frame platform except asindicated:
3,480 mm (137 in) F250/350 regular cab, long box3,607 mm (142 in) F250/350 SuperCab, short box3,962 mm (156 in) F250/350 Crew Cab, short box4,014 mm (158 in) F250/350 SuperCab, long box4,369 mm (172 in) F250/350 Crew Cab, long box4,470 mm (176 in) F450 Crew Cab, narrow frame
F350550 chassis cab(s) available with the following wheelbase lengths:3,581 mm (141 in) F350/450 chassis cab, narrow frame4,115 mm (162 in) F350/550 chassis cab, narrow frame4,191 mm (165 in) F350/550 chassis cab, narrow frame4,470 mm (176 in) F350/550 chassis cab, narrow frame4,795 mm (189 in) F350/550 chassis cab, narrow frame5,085 mm (200 in) F450/550 chassis cab, narrow frame5,105 mm (201 in) F450/550 chassis cab, narrow frame
Bolt on front and rear bumpersOptional flexgate tailgate with integrated pullout stepStructural adhesive used in roof reinforcements, cab back panel and pickup box wheelhouse outertoinner panelSound deadener material applied to floor pan(s)Pickups available with Tough Bed® liner material
The Tough Bed® liner material has special service requirements. If repairs are required, refer to Pickup Bed Side Panelin this section.
For dimensional information, refer to the following illustrations.
Body Margins
NOTE:Dimensions apply to all cab and box styles unless otherwise indicated. Dimensions apply to right and left side.
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Item Description Specification Flushness Specification1 Grille opening panel to bumper 26 mm (1.02 in) ± 6.0 mm (0.23 in)
2 Hood to grille 5.5 mm (0.22 in) ± 3.0 mm (0.118in)
3.0 mm (0.118 in) ± 3.0mm (0.118 in)
3 Headlamp to hood 10.5 mm (0.413 in) ± 3.0 mm (0.11in)
4 Headlamp to grille 8.0 mm (0.31 in) ± 5.0 mm (0.20)
5 Fender to hood 4.2 mm (0.165 in) ± 2.0 mm (0.078in)
4.3 mm (0.169 in) ± 2.5mm (0.098 in)
6 Headlamp to fender 3.0 mm (0.11 in) ± 2.0 mm (0.07 in) 0.0 mm ( in) ± 2.0 mm(0.078 in)
7 Fender to door 5.0 mm (0.19 in) ± 2.5 mm (0.098in)
8 Front door to Apillar 8.0 mm (0.31 in) ± 2.0 mm (0.07 in) 0.0 mm ( in) ± 2.5 mm(0.098 in)
9 Front and rear door to roof 5.0 mm (0.19 in) ± 2.0 mm (0.07 in)
10 Front door to corner panel (regular cab) front door to rear door(SuperCab, Crew Cab)
7.0 mm (0.275 in) ± 2.5 mm (0.098in)
0.0 mm ( in) ± 3.0 mm(0.118 in)
11 Rear door to corner panel 5.0 mm (0.20 in) ± 2.5 mm (0.098in) (Crew Cab)6.0 mm (0.236 in) ± 3.0 mm (0.118in) (SuperCab)
0.0 mm ( in) ± 3.0 mm(0.118 in)
Body Margins
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Item Description Specification Flushness Specification12 Tailgate to bumper 32.0 mm (1.25 in) ± 6.0 mm (0.23 in)
13 Tail lamp assembly to tailgate 6.0 mm (0.23 in) ± 3.5 mm (0.13 in) 1.5 mm (0.059 in) ± 3.0 mm (0.118 in)
14 Tailgate to box 5.0 mm (0.19 in) ± 3.5 mm (0.13 in) 0.9 mm (0.035 in) ± 2.0 mm (0.078 in)
15 Tail lamp to box 2.0 mm (0.07 in) ± 2.0 mm (0.07 in)
Underhood Dimensions
NOTE:Measurements are obtained on center, unless otherwise indicated.
Front Structure Dimensions
NOTICE: The front structure rails cannot be sectioned and must be serviced at the original factory seam locations or as anassembly if damaged. It is mandatory that the replacement section be installed as delivered at the original factory seamlocations or collision energy management can be compromised.
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NOTE:Front structure to Apillar seams require sealing after installation. For additional information, refer to Sealersin this section.
Body Side Dimensions
Regular Cab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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SuperCab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Crew Cab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Tailgate Opening Dimensions
NOTE:Measurements are obtained on center, unless otherwise indicated. Dimensions apply to all pickup box styles.
Frame and Underbody Dimensions
NOTE:A structural frame rail service kit is available for this vehicle. Refer to the included instruction sheet for installation guidelines,and Frame Membersin this section.
Frame Dimensions Pickup, 3,480 mm (137 in) Wheelbase
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NOTE:Measurements are obtained on center, unless otherwise indicated.
Frame Datum Height Pickup, 3,480 mm (137 in) Wheelbase
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions Pickup, 3,607 mm (142 in) Wheelbase, F250/350, Wide Frame
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NOTE:Measurements are obtained on center, unless otherwise indicated.
Frame Datum Height Pickup, (142 in) Wheelbase, F250/350, Wide Frame
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions Pickup, 3962 mm (156 in) Wheelbase, F250/350, Wide Frame
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height Pickup, 3962 mm (156 in) Wheelbase, F250/350, Wide Frame
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions Pickup, 4,013 mm (158 in) Wheelbase, F250/350, Wide Frame
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height Pickup, 4013 mm (158 in) Wheelbase
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions 3,581 mm (141 in) Wheelbase, F350/450 Chassis Cab, Narrow Frame
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height 3,581 mm (141 in) Wheelbase, F350/450 Chassis Cab, Narrow Frame
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions 4,115 mm (162 in) Wheelbase, Chassis Cab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height 4,115 mm (162 in) Wheelbase, Chassis Cab
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions 4191 mm (165 in) Wheelbase, Chassis Cab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height 4191 mm (165 in) Wheelbase, Chassis Cab
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions Pickup, 4,369 mm (172 in) Wheelbase
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height Pickup, 4,369 mm (172 in) Wheelbase
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions 4,470 mm (176 in) Wheelbase, F350550 Chassis Cab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height Chassis Cab, 4,470 mm (176 in) Wheelbase, Chassis Cab
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions 4724 mm (186 in) Wheelbase, Chassis Cab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height 4,724 mm (186 in) Wheelbase, Chassis Cab
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions 4,801 mm (189 in) Wheelbase, Chassis Cab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height 4,801 mm (189 in) Wheelbase, Chassis Cab
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions 5,080 mm (200 in) Wheelbase, Chassis Cab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height 5,080 mm (200 in) Wheelbase, Chassis Cab
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Frame Dimensions 5105 mm (201 in) Wheelbase, Chassis Cab
NOTE:Measurements are obtained on center, unless otherwise indicated.
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Frame Datum Height 5105 mm (201 in) Wheelbase, Chassis Cab
NOTE:Datum height determined measuring from lower edge of holes or slots, on center, unless otherwise indicated.
Copyright © 2014 Ford Motor Company
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Copyright 2007 2014 Service Repair Solutions, Inc.