Technical Presentation Friction Costs when Replacing a Full Frame. January 24, 2013

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1 Technical Presentation Friction Costs when Replacing a Full Frame January 24, 2013

2 2001 Ford F150 Barrier Crash Test

3 2011 Ford F150 Barrier Crash Test

4 What does Range Rover say about repairs, welding or frame component on their BOF vehicles? A. Minor Pulling without heat B. Minor Pulling with controlled heat (977 / 90 sec) C. Pulling to the rear section of the frame (lower strength metals used in the rear) D. Welding cracks less than 50mm (2 inches) E. Welding for bracket replacement only F. None of the above.

8 Rear bumper Reinforcement Note the welds

9 Body of Range Rover with frame removed sitting on a hoist.

10 Both frames sitting side by side New replacement frame Damaged frame With all mechanicals attached

11 Included & Non Included Operations for Frame Replacement

12 Left Front Suspension

13 Are the times for removing the torsion arm & upper control arm included in the removal process, if it is necessary to remove them to remove the drive axle? Upper Control Arm Torsion Arm Link Drive Axle A. Yes B. No C. Don t Know

14 Upper Control Arm and Torsion Rod Disconnected.

15 R&I of the Rear Air Actuated Shock Absorber included or not inclueded? 1. Yes 2. No 3. Don t Know Rear Air Shock absorber

16 R&I of the Rear Air Actuated Shock Absorber included or not included? A. Yes B. No C. Don t Know

17 Are the Body Mounts included or non included operations? 1. Yes 2. No. 3. Not Sure Body Mount

18 Are the Body Mounts included or not included operations? A. Yes B. No C. Not sure

20 Rear Wheel Drive Assembly is an included Operation or not included operation? A. Included B. Not Included C. Not sure

21 Rear Drive Wheel Components Included or Not Included operations? Drive Axle 1. Yes 2. No 3. Not sure Rear Differential

22 Rear Drive Wheel Components Included or Not Included operations? A. Included B. Not Included C. Not sure

23 Wire Harness for Ride height control system Included or Not included? 1. Yes 2. No 3. Not Sure Ride Height Control Wire Loom

24 Wire Harness for Ride height control system Included or Not included? A. Yes B. No C. Not sure

26 Question Which wire loom is Mitchell referencing in their P pages? A. Engine to Body B. Attached to the frame C. All Wire Looms

27 Bleeding the brake system included or not included? 1. Included 2. Not included Brake Caliper

28 Is the rear drive shaft included or not included? 1. Included 2. Not Included Rear Drive Shaft

29 Front drive shaft included with a 4 wheel drive vehicle included with the rear differential? 1. Yes 2. No 3. Don t Know Front wheel drive Shaft on 4 wheel Drive vehicle

30 Front drive shaft included with the rear differential on a 4 wheel drive vehicle? A. Yes B. No C. Not sure

31 Muffler Heat Shields

32 Rear Hydraulic Sway Bar

33 Suspension Air Compressor

34 Ride Height Control Sensor

35 Did you know this this part needs to be filled by the dealer only, because the procedure requires a scan tool that only available to Range Rover Dealers. 1. I knew 2. I didn t know Hydraulic Sway Bar Pump

36 Did you know this part needs to be filled by the dealer only? The procedure requires a scan tool that is only available to Range Rover Dealers. A. I did know B. I did not know

37 Hydraulic Sway Bar Lines 2 Lines go to the front hydraulic sway bars, 2 go to the rear sway bar and 2 go to the pump.

38 2 Lines go to the front hydraulic sway bars, 2 go to the rear sway bar and 2 go to the pump.

39 Is the Catalytic converter included operation with the muffler system? Catalytic Converter 1. Included 2. Not Included 3. Don t know

40 Is the Catalytic converter an included operation with the muffler system? A. Yes B. No C. Not sure

41 Question Is this part of the fuel tank assembly or is it a separate part? 1. Part of an assembly 2. Separate part and operation 3. No idea Fuel Filler Neck Assembly

42 Is this part of the fuel tank assembly or is it a separate part? A. Part of the assembly B. Separate part and operation C. I have No idea

44 Is the R&I of the rear tie rod an included operation or non included operation? 1. Included 2. Not included Rear tie rod

45 Is the R&I of the rear tie rod an included operation or not included operation? A. Included B. Not Included

47 New Frame all mechanicals attached

48 Were all these parts included or not included?

OVERVIEW FIGURE 1 AXLE REINFORCEMENT BRACKET INSPECTION

OVERVIEW FIGURE 1 AXLE REINFORCEMENT BRACKET INSPECTION PAGE 1 OF 7 CERTAIN 1998-2003 MODEL YEAR WINDSTAR VEHICLES REPAIRED UNDER SAFETY RECALL 10S13 WITH REAR AXLE REINFORCEMENT BRACKETS REAR AXLE INSPECTION AND REPAIR OVERVIEW Determine if repairs completed