FRAME—RIVET REPLACEMENT WITH BOLTS— Article No.

SERVICE TIPS 97-4-7

FORD: 1980-1996 BRONCO

1980-1997 ECONOLINE, F-150-350 SERIES
1983-1997 RANGER
1984-1990 BRONCO II
1986-1997 AEROSTAR
1988-1997 F SUPER DUTY, F-47
1991-1997 EXPLORER

This TSB article is being republished in its entirety d. Drive out the rivet with a punch and
to include 1997 model year vehicles. hammer.

ISSUE 3. Line ream the hole to the replacement bolt

Damaged or loose frame rivets should be replaced
with approved service bolts. WELDING IS NOT
ACCEPTABLE.
ACTION
If service is required, replace standard rivets with
approved service bolts. Refer to the following
Service Procedure for details.
SERVICE PROCEDURE
NOTE
THE “HUCK” RIVET BETWEEN THE #1
CROSSMEMBER AND THE LH FRAME RAIL
SHOULD BE SERVICED PER TSB 91-25-18. THIS
PROCEDURE DOES NOT APPLY.
1. Inspect for a loose or damaged rivet.
nominal size with a hole tolerance of ±0.127mm
(0.005″).
4. Free hole of burrs after reaming to allow bolt
head and nut to seat properly.
5. Select the bolt length to have a minimum of
two (2) threads protruding from outer face of
nut. Refer to the following Bolt Selection Chart
for correct parts usage.
NOTE
IF A FLANGE HEAD NUT AND BOLT ARE NOT
AVAILABLE, GRADE 5 HEX HEADS MAY BE
SUBSTITUTED WITH ONE (1) FLATWASHER
REQUIRED UNDER THE NUT AND ONE (1)
FLATWASHER REQUIRED UNDER THE BOLT
HEAD.

2. Remove any damaged or loose rivets.
a. Drill a 3.175mm (1/8″) hole through the
rivet.
b. Redrill the same hole through the shank of
the rivet.
• Use an 8.731mm (11/32″) drill for 3/8″
and 10mm rivets.
• Use a 9.525mm (3/8″) drill for 11.113mm
(7/16″) rivets.
c. Remove the rivet head with an air chisel.
6. Check to be sure there is a 12.7mm (1/2″)
minimum clearance of bolt to adjacent
components, except engine and transmission,
which must have at least 19.05mm (3/4″)
clearance to allow for powertrain roll.
7. Tighten the bolts to the specifications shown in
the Bolt Selection Chart.
NOTE
GRADE 8 BOLTS MAY BE SUBSTITUTED FOR
ANY APPLICATION.

PROOF 30-MAR-00 LTP96010R1 LTP96010R1 PAGE 1

 Article No. 97-4-7 Cont’d.

BOLT SELECTION CHART

Bolt Part Washer Part Nut Part

Rivet Diameter Bolt Size Number Number Number Torque Specifications

3/8″ and 10mm 7/16″-14x1.25″ 56561-S2 Not Required 382400-S2 45-68 N•m (33-50 lb-ft)
7/16″-14x1.75″ 56563-S2 Not Required 382400-S2 45-68 N•m (33-50 lb-ft)

7/16″ 1/2″-13x1.5″ (Grade 56783-S100 Not Required 33773-S2 72-102 N•m (53-75 lb-ft)
5)
1/2″-13x2.0″ (Grade 383896-S2 44879-S2 33773-S2 102-142 N•m (75-105
8) lb-ft)

PART NUMBER PART NAME Bumper Warranty Coverage

56561-S2 Bolt (7/16″-14x1.25″) For 1992-97 Model Year
56563-S2 Bolt (7/16″-14x1.75″) Vehicles, Basic Warranty
56783-S100 Bolt (1/2″-13x1.5″) Coverage For All Other
383896-S2 Bolt (1/2″-13x2.0″) Model Year Vehicles
382400-S2 Nut
33773-S2 Nut OPERATION DESCRIPTION TIME
44879-S2 Washer 970407A Replace Rivet 0.5 Hr.
DEALER CODING
OTHER APPLICABLE ARTICLES: 96-4-11 CONDITION
SUPERSEDES: 96-15-11 BASIC PART NO. CODE
WARRANTY STATUS: Eligible Under The 5005 57
Provisions Of Bumper To OASIS CODES: 304000, 305000, 390000

PAGE 2 LTP96010R1 LTP96010R1 PROOF 30-MAR-00