Hey guys, brand new member here. I just purchased a 94 F150 XLT, 5.0 V8. Crazy low mileage and the cleanest interior I've ever seen on one this age, but it did have some front end damage. Guy I bought it from had put on a new junkyard hood. He also included a brand new grille, header panel, and set of headlights and headlight assemblies. In short, I have everything I need. Here's the problem I'm running into, and maybe I'm just missing something because I'm new at this...

My friend and I were about to begin prepping it for the front end assembly when we noticed the core (radiator) support was significantly buckled. We figured that was no good, so we disassembled and detached it (which, by the way, was quite the task). After getting it off, we worked out the buckle best we could. It's pretty straight now, at least according to my eye, but I may still buy one from the junkyard as a replacement. Okay, now we're finally to the problem...the header panel doesn't seem to fit the core support. The bolts on the latter do not fit the holes on the former. The core support is the one that originally came on the truck, and (according to the internet) the model number (FD71003B) on the provided header panel matches my year and model. Also, the measurements match up to the parts I've found on the internet. Just under 67" from end to end on top of the radiator panel, just over 70" from end to end on the front. The header panel is 72" from end to end. The bolt holes on the panel, however, come to right at 70.5", while the bolts on the radiator support clock in about 60.75". I first thought this was due to the buckling, but I don't think that's it. This 3/4 of an inch is really making things hard on me, haha. I can force the panel to fit, seeing that it's plastic, but I doubt that's the solution. My friend, who knows a lot more about this stuff than me, certainly doesn't think that's wise. He's convinced the panel isn't the right part, but, as I said before, the model number certainly matches. Anybody have any insight on this? Thanks!

Aso, sorry for the long post. I'm new, so if I've left out pertinent information or broken board etiquette in any way, please let me know.

 

The 2 bolts at either end should go through the header panel, the wing on the core support and into the fender

 

Thanks for the reply. That's the issue. I don't have it in front of me now, but I'm trying to recall exactly what it looks like. The core support wings have the bolts built in, and they fit perfectly through the holes on either side of the header panel. Unfortunately, the opposite side of whichever one I place on the bolts does not fit. The header panel is simply too long. I can't tell if this is an instance of an aftermarket part being poorly fitted, or if something else is going on. I think I'm going to have to just take a trip to the junkyard and compare pieces.

 

Any pix could help also.

 

For sure on the pics. The only ones I have on my phone don't show enough detail for the parts to which I'm referring. I'll take some when I get home around 8.

 

Okay guys, here's a few pics. Thanks again for the responses.

Core itself:


Header fitting on left bolts:



Header, once fitted on left bolts, not fitting on right:


I can easily push the panel back and onto the bolts while keeping it secure on the opposite side's bolts. This, of course, simply pushes the middle out a bit. Now that I've set the grille in place and had a look at it, I'm beginning to think that that's how the panel is designed and that I've simply been overthinking it. My only concern is how it sits where the hood latch assembly goes. Is it supposed to be so off centered? It seems, once the panel is worked on and the grille in place, that the Ford logo is dead centered. Just now sure on those bolt holes for the latch assembly.

Latch:





And one with the tape for good, well, measure





As I said in the op, the whole top of the assembly measures just shy of 67 inches.

So, what's the verdict? Just force the fit and call it a day? Thanks again for all y'all's help.

 

Nope. That's not right.
You should be able to just set the header panel into place over those little pegs that stick out. And it should be centered.
So the header panel is wrong, the rad support is short, or the wings on the end are improperly installed.
I usually pull two or three of those front ends apart every month and I've never seen one even anywhere close to not lining up perfect; no bending, no stretching, no messing around - you should be able to just place it on those 4 pegs.
I think the fenders go on the pegs first, then the header panel if I'm recalling this correctly.

 

I'll take a look at some stuff tomorrow - I'm thinking the header panel may be wrong.

 

Okay, thanks. I'll check back in tomorrow. Let me know if you need any more info from me. I agree that the wrong panel makes the most sense. That said, I'm confused because the panel does seem to be centered. The logo is smack in the middle of the core support. The latch support, however, is not centered. Is that normal?

 

I agree with Chris, there's a problem with the fit. Wrong part?