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ders, which creates more power during combustion.
major component systems (Fig. 14) (Fig. 15) :
The turbocharger assembly consists of † Turbine section † Compressor section † Bearing housing † Wastegate
four (4)
Fig.13INTAKEMANIFOLDTOAIRINLETDUCT
RUBBERSLEEVE
1 - INTAKE MANIFOLD AIR INLET 2 - CLAMPS 3 - AIR INLET DUCT 4 - AIR INLET DUCT RUBBER SLEEVE
(2) Position Special Tool 8462 onto air inlet duct and intake manifold. Using the existing clamps tighten to 8 N·m (72 in. lbs.).
(3) Install the 3447.5 kPa 500 psi (gray) Pressure Transducer (part of OT-CH8520 Transducer Kit) into Special Tool 8462.
(4) Connect the DRB IIIt to the pressure trans- ducer following the instructions supplied with the DRB IIIt.
(5) Enter DRB IIIt into pressure reading mode
and test drive vehicle.
(6) Full laod boost pressure at rated speed will be 158 - 186 kPa (23 - 27 psi.) depending on engine hp rating.. If pressure readings are are not within this range inspect for the following: † Restricted air inlet system † Leak in the charge air cooler system (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM/ CHARGE AIR COOLER AND PLUMBING - DIAG- NOSIS AND TESTING) † Turbocharger wastegate broken or misadjusted † Restricted/high pressure drop across charge air coolerFig.14TurbochargerOperation
1 - TURBINE SECTION 2 - EXHAUST GAS 3 - BEARING HOUSING 4 - COMPRESSOR SECTION 5 - INLET AIR 6 - COMPRESSED AIR TO ENGINE 7 - EXHAUST GAS 8 - EXHAUST GAS TO EXHAUST PIPE
OPERATION
Exhaust gas pressure and energy drive the tur- bine, which in turn drives a centrifugal compressor that compresses the inlet air, and forces the air into the engine through the charge air cooler and plumb- ing. Since heat is a by-product of this compression, the air must pass through a charge air cooler to cool the incoming air and maintain power and efficiency.
Increasing air flow to the engine provides: † Improved engine performance † Lower exhaust smoke density
EXHAUST SYSTEM
11 - 12
TURBOCHARGER (Continued)DR
Fig.15TurbochargerWastegateActuator
1 - TURBOCHARGER 2 - DIAPHRAGM 3 - WASTE GATE ACTUATOR
† Improved operating economy † Altitude compensation † Noise reduction. The turbocharger also uses a wastegate (Fig. 16), which regulates intake manifold air pressure and prevents over boosting at high engine speeds. When the wastegate valve is closed, all of the exhaust gases flow through the turbine wheel. As the intake mani- fold pressure increases, the wastegate actuator opens the valve, diverting some of the exhaust gases away from the turbine wheel. This limits turbine shaft speed and air output from the impeller.
The turbocharger is lubricated by engine oil that is pressurized, cooled, and filtered. The oil is delivered to the turbocharger by a supply line that is tapped into the oil filter head. The oil travels into the bear- ing housing, where it lubricates the shaft and bear- ings (Fig. 17). A return pipe at the bottom of the bearing housing, routes the engine oil back to the crankcase.
The most common turbocharger failure is bearing failure related to repeated hot shutdowns with inade- quate “cool-down” periods. A sudden engine shut down
Fig.16WastegateOperation
1 - SIGNAL LINE 2 - EXHAUST BYPASS VALVE 3 - WASTEGATE 4 - EXHAUST 5 - TURBINE
after prolonged operation will result in the transfer of heat from the turbine section of the turbocharger to the bearing housing. This causes the oil to overheat and break down, which causes bearing and shaft dam- age the next time the vehicle is started.
Letting the engine idle after extended operation allows the turbine housing to cool to normal operat- ing temperature. The following chart should be used as a guide in determining the amount of engine idle time required to sufficiently cool down the turbo- charger before shut down, depending upon the type of driving and the amount of cargo.
DR TURBOCHARGER (Continued)
EXHAUST SYSTEM 11 - 13
Fig.18TurbochargerAirInletHose
1 - AIR INLET TUBE 2 - AIR FILTER HOUSING 3 - TURBOCHARGER
Fig.17TurbochargerOilSupplyandDrain
1 - BEARINGS 2 - OIL SUPPLY (FROM FILTER HEAD) 3 - OIL RETURN (TO SUMP)
TURBOCHARGER (COOL DOWN( CHART
Turbocharger
Idle Time (in
minuetes) Temperature Before Shut
Cool Warm Warm
Warm
Warm
Hot
Down
Less than 1
Driving
Load
Condition
Empty Stop & Go Stop & Go Medium Highway Medium Speeds
Max. GCWR Max. GCWR Max. GCWR
City Traffic
Highway Speeds Uphill Grade
REMOVAL
(1) Disconnect the battery negative cables. (2) Raise vehicle on hoist. (3) Disconnect the exhaust pipe from the turbo- charger elbow(Refer to 11 - EXHAUST SYSTEM/EX- HAUST PIPE - REMOVAL).
(4) Lower vehicle. (5) Disconnect the turbocharger air inlet hose (Fig.
18).
(6) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 19).
(7) Disconnect the charge air cooler inlet pipe from
the turbocharger compressor outlet (Fig. 19).
(8) Remove the turbocharger and gasket from the
exhaust manifold.
Fig.19OilSupplyLineandChargeAirCoolerInlet
Duct
1 - TURBOCHARGERR EXHAUST ELBOW 2 - TURBOCHARGER 3 - OIL SUPPLY LINE 4 - AIR INLET TUBE 5 - TURBOCHARGER COMPRESSOR OUTLET 6 - OIL DRAIN LINE
EXHAUST SYSTEM
11 - 14
TURBOCHARGER (Continued)DR
(9) If the turbocharger is not to be installed imme- diately, cover the opening to prevent material from entering into the manifold.
(10) If replacing the turbocharger, transfer the
compressor outlet and clamp to the new assembly.
(11) Clean and inspect the sealing surface.
CAUTION: The turbocharger is only serviced as an assembly. Do not attempt to repair the turbocharger as turbocharger and/or engine damage can result.
CLEANING
Clean the turbocharger and exhaust manifold
mounting surfaces with a suitable scraper.
INSPECTION
Visually inspect
the turbocharger and exhaust manifold gasket surfaces. Replace stripped or eroded mounting studs.
that go completely through.
The following cracks are NOT acceptable:
(1) Visually inspect the turbocharger for cracks. † Cracks in the turbine and compressor housing † Cracks in the mounting flange that are longer † Cracks in the mounting flange that intersect † Two (2) Cracks in the mounting flange that are
than 15 mm (0.6 in.).
bolt through-holes.
closer than 6.4 mm (0.25 in.) together.
(2) Visually inspect the impeller and compressor wheel fins for nicks, cracks, or chips. Note: Some impellers may have a factory placed paint mark which, after normal operation, appears to be a crack. Remove this mark with a suitable solvent to verify that it is not a crack.
(3) Visually inspect the turbocharger compressor housing for an impeller rubbing condition (Fig. 20). Replace the turbocharger if the condition exists. (4) Measure the turbocharger axial end play:
(a) Install a dial indicator as shown in (Fig. 21).
Zero the indicator at one end of travel.
(b) Move the impeller shaft fore and aft and record the measurement. Allowable end play is 0.026 mm (0.0001 in.) MIN. and 0.127 mm (0.005
in.) MAX. If the recorded measurement falls out- side these parameters, replace the turbocharger assembly. (5) Measure the turbocharger bearing radial clear-ance:
(a) Insert a narrow blade or wire style feeler gauge between the compressor wheel and the hous- ing (Fig. 22).
(b) Gently push the compressor wheel toward
the housing and record the clearance.
(c) With the feeler gauge in the same location, gently push the compressor wheel away from the housing and again record the clearance.
(d) Subtract
the smaller clearance from the larger clearance. This is the radial bearing clear- ance.
(e) Allowable radial bearing clearance is 0.33
mm (0.013 in.) MIN. and 0.50 mm (0.020 in.) MAX. If the recorded measurement falls outside these specifications, replace the turbocharger assembly.Fig.20InspectCompressorHousingforImpeller
RubbingCondition
Fig.21MeasureTurbochargerAxialEndPlay
INSTALLATION
(1) Install the turbocharger. Apply anti-seize to the studs and then tighten the turbocharger mounting nuts to 43 N·m (32 ft. lbs.) torque.
(2) Install the oil drain tube to the turbocharger (Fig. 19). Tighten the drain tube bolts to 24 N·m (18
ft. lbs.) torque.DR TURBOCHARGER (Continued)
EXHAUST SYSTEM 11 - 15
Fig.22MeasureTurbochargerBearingRadial
Clearance
1 - FEELER GAUGE
(3) Pre-lube the turbocharger. Pour 50 to 60 cc (2 to 3 oz.) clean engine oil in the oil supply line fit- ting. Carefully rotate the turbocharger impeller by hand to distribute the oil thoroughly.
(4) Install and tighten the oil supply line to 24
N·m (18 ft. lbs.) torque.
(5) Position the charge air cooler inlet pipe to the turbocharger. With the clamp in position, tighten the clamp nut to 11 N·m (95 in. lbs.) torque.
(6) Position the air inlet hose to the turbocharger (Fig. 18). Tighten the clamp to 11 N·m (95 in. lbs.) torque.
(7) Raise vehicle on hoist. (8) Connect the exhaust pipe to the turbocharger and tighten the bolts to 34 N·m (25 ft. lbs.) torque.
(9) Lower the vehicle. (10) Connect the battery negative cables. (11) Start the engine to check for leaks.
CHARGE AIR COOLER AND PLUMBING DESCRIPTION
The charge air system (Fig. 23) consists of the charge air cooler piping, charge air cooler and intake air grid heater.
The charge air cooler is a heat exchanger that uses air flow from vehicle motion to dissipate heat from the intake air. As the turbocharger increases air pressure, the air temperature increases. Lowering the intake air temperature increases engine effi- ciency and power.
Fig.23IntakeAirCirculation
1 - CHARGE AIR COOLER 2 - AIRFILTER 3 - TURBOCHARGER
ized air from the turbocharger then flows forward through the charge air cooler located in front of the radiator. From the charge air cooler the air flows back into the intake manifold.
DIAGNOSIS AND TESTING - CHARGE AIR COOLER SYSTEM - LEAKS
Low turbocharger boost pressure and low engine performance can be caused by leaks in the charge air cooler or it’s plumbing. Fuel staining on the exhaust manifold can also be an indication that there are leaks in the air system.The following procedure out- lines how to check for leaks in the charge air cooler system.
(1) Loosen clamp and remove air inlet hose from
turbocharger.
(2) Insert Special Tool 9022 Adapter into the turbo- charger inlet. Tighten tool clamp to 8 N·m (72 in. lbs.).
CAUTION: Do not apply more than 138 kPa (20 psi) air pressure to the charge air cooler system, sever damage to the charge air cooler system may occur.
(3) Connect a regulated air supply to air fitting on Special Tool 9022 Adapter. Set air pressure to a Max- imum of 138 kPa (20 psi).
(4) Using soapy water check the rubber sleeves,
charge air cooler and intake manifold for leaks.
REMOVAL
OPERATION
Intake air is drawn through the air cleaner and into the turbocharger compressor housing. Pressur-
WARNING: IF THE ENGINE WAS JUST TURNED OFF, THE AIR INTAKE SYSTEM TUBES MAY BE HOT.
EXHAUST SYSTEM
11 - 16
CHARGE AIR COOLER AND PLUMBING (Continued)DR
(1) Disconnect the battery negative cables. (2) Discharge the A/C system (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - STAN- DARD PROCEDURE) and remove the A/C condenser (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/A/C CONDENSER - REMOVAL) (if A/C equipped).
(3) Remove
cooler (Refer to 7 - COOLING/TRANSMISSION/TRANS COOLER - REMOVAL).
transmission auxiliary
the
(4) Remove the boost tubes from the charge air
cooler (Fig. 24).
(1) If the engine experiences a turbocharger failure or any other situation where oil or debris get into the charge air cooler, the charge air cooler must be cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.
(4) Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. (5) Continue flushing until all debris or oil are
removed.
(5) Remove the charge air cooler bolts. Pivot the
(6) Rinse the cooler with hot soapy water to
charge air cooler forward and up to remove.
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. Replace the charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge Air Cooler Tester Kit #3824556. This kit is available through Cumminst Service Products. Instructions are provided with the kit.
INSTALLATION
(1) Position the charge air cooler. Install the bolts
and tighten to 2 N·m (17 in. lbs.) torque.
(2) Install
the air intake system tubes to the charge air cooler. With the clamps in position, tighten the clamps to 11 N·m (95 in. lbs.) torque.
(3) Install
the transmission auxiliary cooler (if equipped) (Refer to 7 - COOLING/TRANSMISSION/ TRANS COOLER - INSTALLATION).
(4) Install the A/C condenser (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING/A/C CONDENSER - INSTALLATION). Recharge A/C system (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE).
(5) Connect the battery negative cables. (6) Start engine and check for boost system leaks.
Fig.24AirIntakeSystemTubes
1 - BOLT 2 - CHARGE AIR COOLER 3 - CLAMP 4 - BOOST TUBE
CLEANING
CAUTION: Do not use caustic cleaners to clean the charge air cooler. Damage to the charge air cooler will result.
NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced.
DR
FRAMES & BUMPERS
13 - 1
FRAMES & BUMPERS
TABLE OF CONTENTS
page
page
BUMPERS
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . . 1
FRONT AIR DAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2FRONT BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2FRONT FASCIA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3REAR BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4FRAME
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY
FRONT FRAME RAIL TIP REPLACEMENT . . . . 4
STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT . . . . . . . . . . . . . 15
BUMPERS SPECIFICATIONS - TORQUE
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 17
. . . . . . . . . . . . 23
SPECIFICATIONS - TORQUEFRONT CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23FRONT SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24TRANSMISSION CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25TRAILER HITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25TRANSFER CASE SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26FRONT TOW HOOK ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26TORQUE SPECIFICATIONS
DESCRIPTION
Front bumper center bracket nuts
Front bumper stud plate nuts
License plate hitch reinforcement bolts
Rear bumper support bracket stud plate nuts Rear bumper support bracket to hitch bolts
Rear bumper to hitch bolts
N·m 95
95
54
54
54
54Ft. Lbs.
In. Lbs.
70
70
40
40
40
40— — — — — —
13 - 2
FRAMES & BUMPERS
FRONT AIR DAM REMOVAL
FRONT BUMPER REMOVAL
DR
(1) Using a trim stick C-4755 or equivalent,
remove the fog lamp trim bezels. (Fig. 1)
(2) Remove the air dam screws through the fog
lamp opening (1 per side).
(3) Remove the two outboard screws. (4) Remove the three middle screws and remove
the air dam.
Fig.1FOGLAMPBEZEL
1 - BUMPER 2 - BEZEL
INSTALLATION
(1) Position the air dam onto the bumper and seat
the carrot type fasteners fully.
(2) Starting at the center screw install the three
middle screws.
ing.
(3) Install the screws through the fog lamp open-
(4) Install the two outboard screws. (5) Position the fog lamp trim bezels into the
bumper and seat fully.
(1) Using a grease pencil or equivalent, mark the position of the bumper on the frame rail tip to aid installation.
(2) Disconnect the fog lamp electrical connector at
the left frame rail.
device.
(3) Support the bumper with a suitable lifting
(4) Remove the center bracket nuts and bolts and
remove bumper. (Fig. 2)
Fig.2BUMPERSUPPORTBRACKET-TYPICAL
1 - FASCIA - SPORT MODEL 2 - SUPPORT BRACKET 3 - FASCIA SUPPORT BRACKET 4 - WHEELHOUSE SPLASH SHIELD SUPPORT BRACKET 5 - BUMPER CENTER BRACKET 6 - NUTS (4 PER SIDE) 7 - FRAME RAIL TIP 8 - CENTER BRACKET NUTS (2 PER SIDE) 9 - CENTER BRACKET BOLTS ASSEMBLY (1 PER SIDE) 10 - FOG LAMP
INSTALLATION
(1) Install the bumper onto the frame rails and position the wheelhouse splash shield into the sup- port brackets.
(2) Install the bolts and nuts. (3) Line up the bumper with the marks made pre- viously and tighten the bolts and nuts to 95 N·m (70
ft. lbs.).(4) Check and adjust the bumper alignment as necessary. (Refer to 23 - BODY/BODY STRUCTURE/ GAP AND FLUSH - SPECIFICATIONS)
DR
FRAMES & BUMPERS
13 - 3
FRONT FASCIA REMOVAL
ST/SLT/SLT+ - FASCIA REMOVAL
(1) Remove the two screws at each trailing edge of
the fascia. (Fig. 3)
(2) Using a trim stick C-4755 or equivalent, care- fully release the six lower clips and remove the close out panel.
(3) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(4) Remove and discard the four push pin fasten-
ers and remove the fascia.
Fig.4SPORTFASCIA
1 - STEP PAD 2 - FASCIA (SPORT MODEL ONLY) 3 - SCREWS (3 PER SIDE) 4 - UPPER FASCIA SUPPORT BRACKET 5 - WHEELHOUSE SPLASH SHIELD BRACKET 6 - INBOARD BUMPER BRACKET ATTACHMENTS 7 - PUSH PIN FASTENERS (4) 8 - LOWER SCREWS (5)
INSTALLATION
NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad.
Fig.3UPPERFASCIA-ST/SLT/SLT+
ST/SLT/SLT+ FASCIA INSTALLATION
1 - STEP PAD 2 - UPPER FASCIA (ST/SLT/SLT+ MODEL ONLY) 3 - INBOARD BUMPER BRACKET ATTACHMENTS 4 - SCREWS (4) 5 - PUSH PIN FASTENERS (4)
SPORT FASCIA REMOVAL (1) Raise and support
to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
the vehicle.
(Refer
(2) Remove the three screws at each trailing edge
of the fascia. (Fig. 4)
(3) Remove the five lower screws. (4) Remove and discard the four upper push pins. (5) Using a trim stick C-4755 or equivalent, care- fully release the six lower clips and remove the close out panel.
(6) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(7) Spread the fascia out at the wheels and remove
from the vehicle.
(1) Install the fascia. (2) Position the close out panel and seat the 6
lower clips fully.
(3) Install four new upper push pin fasteners. (4) Position the step pad onto the fascia and fully
seat the attachment clips.
(5) Align the fascia to the fender with a 19 mm (0.75 inch) gap and install the two screws at each trailing edge of the fascia.
SPORT FASCIA INSTALLATION
(1) Position the fascia onto the bumper. (2) Position the step pad onto the fascia and fully
seat the attachment clips.
(3) Install four new upper push pin fasteners. (4) Install the five lower screws. (5) Install the three screws at each trailing edge of
the fascia.
13 - 4
FRAMES & BUMPERS
DR
REAR BUMPER REMOVAL
(1) Raise and support
to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
the vehicle.
(Refer
(2) Remove the license plate. (3) Remove the bolts behind the plate. (4) Disconnect the license plate light electrical con-
nectors.
(5) Disconnect the trailer light connector electrical
connection, if equipped.
(6) Remove the two bolts along the front upper
edge of the bumper near the frame tips.
(7) Support the bumper with a suitable lifting device. (8) Remove the bolts attaching the bumper support
brackets to the trailer hitch. (Fig. 5)
Fig.5TRAILERHITCH
1 - HITCH 2 - HITCH BOLTS (4) 3 - BUMPER BRACKET BOLTS (4) 4 - BUMPER SUPPORT BRACKETS
INSTALLATION
(1) Align the holes in the bumpers to the trailer
hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts,
loosely.
(3) Install the front upper edge to the trailer hitch
bolts and tighten to 54 N·m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch
bolts and tighten to 54 N·m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54
N·m (40 ft. lbs.).
N·m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54
(7) Connect the trailer light connector electrical
connection, if equipped.
(8) Connect the license plate light electrical con-
nectors.
(9) Install the license plate.
FRAME
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT FRAME RAIL TIP REPLACEMENT
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND- ING OR WELDING METAL, SERIOUS EYE INJURY CAN RESULT. † BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING GRINDING OR WELDING, VERIFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN CONTACT WITH REPAIR AREA, PERSONAL INJURY CAN RESULT. † DO NOT ALLOW OPEN FLAME OR HEAT AND METAL SPATTER FROM ARC WELDING, TO CON- TACT PLASTIC BODY PANELS. FIRE OR EXPLO- SION CAN RESULT. † WHEN WELDED FRAME COMPONENTS ARE REPLACED, ENSURE COMPLETE PENETRATION WELD IS ACHIEVED DURING INSTALLATION. IF NOT, DANGEROUS OPERATING CONDITIONS CAN RESULT. † STAND CLEAR OF CABLES OR CHAINS ON PULLING EQUIPMENT DURING FRAME STRAIGHT- ENING OPERATIONS, PERSONAL INJURY CAN RESULT. † DO NOT VENTURE UNDER A HOISTED VEHI- CLE THAT IS NOT SUPPORTED ON SAFETY STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and later) are not designed for snow plow equipment. The front collision repair tips must not be installed on any truck equipped with a snow plow, or even intended to be equipped with a snow plow.
CAUTION: This procedure is designed to replace the front frame rail tips that have been damaged in the crush initiator zones. Prior to any cutting, the vehicle must be mounted on the appropriate frame repair equipment (“frame rack”), checked with three dimensional measuring equipment, and the neces- sary pull corrections made. If damage remains in the frame beyond the area covered by this service part after the pull, the frame must be replaced in its entirety.
FRAMES & BUMPERS
13 - 5
(7) Make a vertical mark on the inside and outside face of the frame rail 112 mm (4.5 in.) from the for- ward edge of the PLP hole in the sides of the rail. (Fig. 8)
(8) Using a straightedge, connect the two lines on
the top and bottom of the rail.
(9) Using the service tip as a guide, re-check your cut lines to ensure the service tip will fit when the cut is made.
CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in this procedure. This is due to the inaccurate nature of the cut-line and the fact that the high temperatures achieved during flame or plasma cutting will change the metal char- acteristics and may weaken the frame and/or repair location.
(10) Using a reciprocating saw or equivalent, care- fully cut and remove the damaged frame rail tip. (Fig. 7)
DR FRAME (Continued)
CAUTION: Do not reuse damaged fasteners, quality of repair would be suspect. Failure to use only pro- duction fasteners or fasteners of equivalent hard- ness can result in loosening or failure. Do not drill any holes in the frame that are not specifically out- lined in this or other, DaimlerChrysler procedure as frame rail failure can result. When using heat to straighten frame components do not exceed 566°C (1050°F), metal fatigue can result.
NOTE: Procedures for 4X2 and 4X4 are common except as noted in this procedure.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEEL- HOUSE SPLASH SHIELD - REMOVAL)
(3) Remove the bolts and position aside the wire
harness and grounds, if required.
(4) Remove the front bumper.
(Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT BUMPER - REMOVAL)
(5) Loosen and lower the stabilizer bar mount and (Refer to 2 - SUSPENSION/FRONT/STABI-
bar. LIZER BAR - REMOVAL)
(6) Remove the front cab mount bolt to the Front
End Sheet Metal (FESM) bracket. (Fig. 6)
Fig.7FRAMECUTLOCATION
1 - REPAIR ROOT OPENING 2 - SERVICE SLEEVE 3 - PRINCIPLE LOCATING POINT (PLP) 4 - SUSPENSION BRACKETS 5 - FRAME 6 - FRAME CUTOFF LOCATION - 112 mm (4.5 in.) 7 - FRAME SERVICE TIP
Fig.6REPLACEMENTFRAMETIP
1 - FRONT END SHEET METAL (FESM) BRACKET 2 - CAB INSULATOR 3 - RING-FILLET WELD/HOLE 4 - PRINCIPLE LOCATING POINT (PLP) 5 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.) 6 - FRONT CAB MOUNT BOLT 7 - REPLACEMENT FRAME TIP
FRAMES & BUMPERS
13 - 6
FRAME (Continued)(11) Assemble the service sleeve. Refer to SER- VICE SLEEVE ASSEMBLY at the end of this proce- dure.
NOTE: Any burned surface coatings will need to be removed from the sleeve prior to installation and application of corrosion preventative coatings.
DR
(12) Smooth and square the cut edges of the origi-
nal frame. (Fig. 7)
(13) Dress the cut edge of the existing frame in
preparation for the new rail tip.
(a) Drill four 13 mm (0.5 in.) diameter holes in the new tip and four more in the existing frame to accommodate ring-fillet welds. Center these holes 19 mm (0.75 in.) from the cut face of the rail and 38 mm (1.5 in.) from the top and bottom of the rail. (Fig. 8)
(b) Bevel the edges of the new tip, existing frame, and ring-fillet holes 25° - 30°. Scribing a line 2 mm from the cut edge and then grinding back to the mark will simplify the bevel creation process and accuracy. (Fig. 9)
(c) Remove any burrs at the holes and beveled
edges.
Fig.9WELDDIMENSIONS
1 - FRAME REPLACEMENT TIP 2 - FRAME RAIL 3 - FRAME DRESS ANGLE 25°-30° 4 - ROOT PASS 5 - COVER PASS 6 - SERVICE SLEEVE 7 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.) 8 - SERVICE SLEEVE
(14) Dry fit the new rail to ensure alignment and
fit and make any adjustments as necessary.
(15) Remove all internal and external OEM e-coat within 51 mm (2.0 in.) of the weld joint on the replacement tip and the existing frame rail.
NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventa- tive coatings.
CAUTION: Shield the surrounding area and compo- nents from exposure to the welding spatter and heat.
Fig.8REPAIRSLEEVEINSTALLATION(TYPICAL) 1 - REPLACEMENT FRAME TIP 2 - FRAME RAIL 3 - SERVICE SLEEVE 4 - CENTER LINE 5 - LOCATOR LINES (2) 6 - HORIZONTAL WELD HOLE LOCATION - 38 mm (1.5 in.)(BOTH FRAME SECTIONS) 7 - LOCATOR LINE DIMENSION - 2 mm (0.08 in.) 8 - VERTICAL WELD HOLE LOCATION - 19 mm (0.75 in.)(BOTH FRAME SECTIONS) 9 - RING FILLET WELD HOLES
DR FRAME (Continued)
FRAMES & BUMPERS
13 - 7
(16) On 4X4 models use the service sleeve as a template to drill a hole in the frame tip to accommo- date the sway bar mounting bolt. (Fig. 12)
(17) Slide the service sleeve into the replacement frame tip and align to the 2 mm (0.08 in.) off center line made previously during the sleeve assembly and tack the ring fillet welds to hold them in place. (Fig. 10) (Fig. 11) (Fig. 12) (Fig. 13)
(18) On 4X4 models, install the sway bar tapping plate and secure with tack welds. (Fig. 12) (Fig. 13)
Fig.104X2SLEEVEINSTALLATION
1 - REPLACEMENT FRAME TIP 2 - FRAME RAIL 3 - SERVICE SLEEVE 4 - PLP 5 - SWAY BAR MOUNTING BRACKET 6 - TAPPING PLATE 7 - ROOT WELD GAP
Fig.114X2SLEEVEINSTALLATION
1 - REPLACEMENT FRAME TIP 2 - ROOT WELD GAP 3 - SERVICE SLEEVE 4 - SWAY BAR MOUNTING BRACKET 5 - TAPPING PLATE
FRAMES & BUMPERS
13 - 8
FRAME (Continued)DR
Fig.124X4TAPPINGPLATE/SLEEVE
INSTALLATION
1 - REPLACEMENT FRAME TIP 2 - FRAME RAIL 3 - SERVICE SLEEVE 4 - PLP 5 - SWAY BAR MOUNTING BRACKET 6 - TAPPING PLATE 7 - ROOT WELD GAP 8 - SLEEVE TAB
(19) Apply ring-fillet welds into the ring-fillet weld holes on the replacement frame tip, using the Weld Process Specifications table. (Fig. 14)
(20) Install the upper FESM insulator onto the replacement tip and position the service sleeve/re- placement tip into the existing frame rail.
(21) Loosely install the lower FESM insulator and
cab mounting bolt.
Fig.134X4TAPPINGPLATE/SLEEVEINSTALLATION 1 - REPLACEMENT FRAME TIP 2 - ROOT WELD GAP 3 - SERVICE SLEEVE 4 - SWAY BAR MOUNTING BRACKET 5 - TAPPING PLATE 6 - SLEEVE TAB
Fig.14RINGFILLETWELD
1 - WELD START LOCATION 2 - WELD END LOCATION 3 - RING-FILLET WELD
DR FRAME (Continued)
(22) Using the appropriate measuring equipment, verify the front end sheet metal bracket’s location in all three (X,Y, and Z) planes of space, and adjust if required. (Fig. 15)
FRAMES & BUMPERS
13 - 9
CAUTION: Shield the surrounding area and compo- nents from exposure to the welding spatter and heat.
(23) When correctly fitted and a weld root gap of 4
mm minimum to 6 mm maximum (0.16 in - 0.24 in) is established, tack the ring fillet welds to hold the tip in position, then complete the ring fillet welds.NOTE: Ring-fillet welds may be filled in with weld material if an improved cosmetic appearance is desired.
(24) Confirm alignment of the replacement frame
rail tip. (Fig. 15)
(25) Final welding should be performed in a skip (stitch) type method to minimize the heat buildup and frame distortion, utilizing the Weld Process Specifications at the end of this section. The pre- ferred method is GMAW (MIG).
(a) Apply root pass welds to the root joint one quadrant at a time, switching to the opposite side of the frame for each quadrant. (Fig. 9)
(b) Clean the welds of any flux and other impu- rities before proceeding with the cover pass welds. (c) Apply the cover pass welds in the same man-
ner as described above. (26) Confirm alignment of the replacement frame
rail tip. (Fig. 15)
NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventa- tive coatings.
(27) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Apply etch-primer to the inside of the frame
rail repair area.
(b) Inside the rail, inject a creeping wax based rust inhibitor compound through the existing holes in the frame ensuring 100% coverage including the space between the original frame rail and the rein- forcing sleeve.
Fig.15FRAMETIPDIMENSIONS
NOTE: All measurements are in mm.
1 - PLP POINT 2 - FRAME 3 - PLP POINT 4 - REPLACEMENT FRAME TIP
FRAMES & BUMPERS
13 - 10
FRAME (Continued)DR
(c) Apply a durable top coat to the outside of the
repair area. (28) Tighten the front cab mounting bolt to the
FESM bracket to 81 N·m (60 ft. lbs.).
(29) Install the stabilizer bar. (Refer to 2 - SUS- PENSION/FRONT/STABILIZER BAR - INSTALLA- TION)
(30) Install
(Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT BUMPER - INSTALLATION)
the front bumper.
(31) Install the wire harness and ground strap if
previously removed and install the bolt.
(a) If necessary, re-drill and tap the ground
strap mounting hole (32) Install the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEEL- HOUSE SPLASH SHIELD - INSTALLATION)
CAUTION: All welds should conform to DaimlerChrysler vehicle engineering process standard “PS 9472”.
WELD PROCESS SPECIFICATIONS
WELDING PROCESS
FLUX CORED ARC
GAS METAL ARC (MIG)*
SHIELDED METAL ARC
Material Thickness Electrode Type
Electrodes Size Inches Electrode Stick Out Polarity
Shielding Gas
3.7 mm to 4.2 mm
Lincoln Electrical Co. Product #: NR-211 MP (Do Not Substitute)
0.045 Tubular
3/89 - 1/29
Electrode 9-9
Work Piece 9+9
Self ShieldedGas Flow Rate Wire Feed Speed (inches per minute)
N/A
110 - 130 Vertical Down 70 - 90 Flat & Overhead
3.7 mm to 4.2 mm
AWS ER70S-3
(Do Not Substitute)
0.035 Solid 1/29 - 5/89
Electrode 9+9
Work Piece 9-975% Ar 25% CO2
25 - 35 CFM
245 - 250 Vertical Down
210 - 225 Flat &
Overhead
(STICK)
3.7 mm to 4.2 mm
** AWS E 7018
3/329
N/AElectrode 9+9
Work Piece 9-9
Self ShieldedN/A N/A
Approximate Amperage
Vertical
Flat & Overhead
Voltage Direction of Welding
110 - 130
70 - 90
15 - 18175
15519 - 20
85 (3/329 Diameter) 90 (3/329 Diameter)
N/A
Vertical
Vertical Down Hill (only)
Vertical Down Hill (only)
Vertical - Up Hill (only)
Flat & Overhead
Flat - Push or Drag
Flat - Push or Drag
Flat - Drag
*First choice - Gas Metal Arc Welding Process: Butt joints - apply two layers (passes) of weld metal. First pass should only fill approximately 1⁄2 the thick- ness. Vertical position welds - maintain electrode wire at leading edge of weld puddle while traveling down hill to produce maximum penetration into the sleeve. These techniques work for FCAW as well.
**E7018 new electrodes may be exposed to the atmosphere for up to ten hours with no harmful effect. Reconditioning schedules should come from the manufacturer.
DR FRAME (Continued) SERVICE SLEEVE ASSEMBLY
NOTE: Two sleeve halves are included with each kit. Modifications as follow, are necessary to create the correct sleeve assembly for each application.
(1) On 4X2 models, the 9lower9 sleeve is made by cutting off the tab and cutting out a notch in the bot- tom sleeve portion. Round the corners of the cut out to keep stress cracks from forming. On 4X4 models the 9lower9 sleeve is used as provided. (Fig. 16)
FRAMES & BUMPERS
13 - 11
(3) The sleeve halves are shipped slightly over- sized to allow custom fitting to each replacement frame rail tip. It is necessary to grind the mating surfaces to achieve the desired snug fit into the replacement tip (rail tube has increasing height rear- ward of the cut line). Once the two sleeve halves are fitted, bevel the edges 25° - 30°.
NOTE: Scribing a line 2 mm from the cut edge and then grinding back to the mark will simplify the bevel creation process and accuracy.
(4) Remove any burrs at the beveled edges. (5) Using the Weld Process Specifications table, weld the two halves of the repair sleeve together. (Fig. 18)
Fig.164X2LOWERSLEEVECUTLOCATION
1 - SERVICE SLEEVE LOWER HALF 2 - CUT DIMENSION 27 mm (1.06 in.) 3 - CUT DIMENSION 36.1 mm (1.42 in) 4 - 4X2 CUTOUT 5 - FRONT TAB CUT LINE (4X2 ONLY)
(2) On both 4X2 and 4X4 models cut off the front
tab on the upper sleeve portion. (Fig. 17)
Fig.17UPPERSLEEVECUTLOCATION
1 - SERVICE SLEEVE UPPER HALF 2 - CUT LOCATION
Fig.18SERVICESLEEVEASSEMBLY
1 - CENTERLINE SCRIBE MARK 2 - WELD SEAM 3 - REAR TAB (4X4 ONLY) 4 - SCRIBE LINE LOCATION 2 mm (0.08 in.) 5 - FRONT TAB (4X4 ONLY)
(6) Clean the welds of any flux and other impuri- ties and grind smooth before proceeding with the installation of the sleeve.
(7) Find the centerline of the sleeve and scribe a centerline mark. Mark two additional lines 2 mm (0.08 in.) on either side of the centerline mark to help ensure the required 4 mm - 6 mm (0.16 in. - 0.24 in.) weld root gap. (Fig. 18)
FRAMES & BUMPERS
13 - 12
FRAME (Continued) STANDARD PROCEDURE - HYDROFORM FENDER RAIL REPAIRSAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND- ING OR WELDING METAL, SERIOUS EYE INJURY CAN RESULT. † BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING GRINDING OR WELDING, VERIFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN CONTACT WITH REPAIR AREA, PERSONAL INJURY CAN RESULT. † DO NOT ALLOW OPEN FLAME OR HEAT AND METAL SPATTER FROM ARC WELDING, TO CON- TACT PLASTIC BODY PANELS. FIRE OR EXPLO- SION CAN RESULT. † WHEN WELDED FRAME COMPONENTS ARE REPLACED, ENSURE COMPLETE PENETRATION WELD IS ACHIEVED DURING INSTALLATION. IF NOT, DANGEROUS OPERATING CONDITIONS CAN RESULT. † STAND CLEAR OF CABLES OR CHAINS ON PULLING EQUIPMENT DURING FRAME STRAIGHT- ENING OPERATIONS, PERSONAL INJURY CAN RESULT. † DO NOT VENTURE UNDER A HOISTED VEHI- CLE THAT IS NOT SUPPORTED ON SAFETY STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality of repair would be suspect. Failure to use only pro- duction fasteners or fasteners of equivalent hard- ness can result in loosening or failure. Do not drill holes in top or bottom frame rail flanges, frame rail failure can result. When using heat to straighten frame components do not exceed 566°C (1050°F), metal fatigue can result.
CAUTION: This repair procedure assumes damage to the right or left hydroform fender rail (Fig. 19). Prior to any repairs, the vehicle must be mounted on the appropriate frame repair equipment (“frame rack”), checked with three dimensional measuring equipment, and necessary pull corrections made. If damage exists in the hydroform fender rail, or cab beyond the area covered by this service procedure after dimensional corrections are made, the hydro- form must be replaced in its entirety. Refer to 23 - BODY/BODY STRUCTURE/WELD LOCATIONS - SPECIFICATIONS, when replacing the entire hydro- form.
DR
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEEL- HOUSE SPLASH SHIELD - REMOVAL)
(3) Remove the fender. (Refer to 23 - BODY/EXTE-
RIOR/FRONT FENDER - REMOVAL)
(4) Remove the A/C condenser, if required. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING/A/C CONDENSER - REMOVAL)
(5) Remove the A/C lines, if required. Refer to the Heating and Air Conditioning section of the manual for recommended procedures.
(6) Remove the radiator assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL)
(7) Remove the air cleaner and support bracket, if required. (Refer to 9 - ENGINE/AIR INTAKE SYS- TEM/AIR CLEANER ELEMENT - REMOVAL)
(8) Remove the integrated power module. (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTE- GRATED POWER MODULE - REMOVAL)
(9) Remove the bolts and position aside the wire
harness and grounds, if required.
(10) Remove the upper
crossmember. (Refer to 23 - BODY/EXTERIOR/UPPER RADIATOR CROSSMEMBER - REMOVAL)
radiator
(11) Remove the headlamp unit.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ HEADLAMP UNIT - REMOVAL)
(12) Remove the front cab mount to the Front End
Sheet Metal bracket (FESM) bolt.
(13) Remove the bolts attaching the lower radiator crossmember to the hydroform fender rail. (Fig. 19)
CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in this procedure. The inaccurate and high temperatures achieved during flame or plasma cutting will change the metal char- acteristics and may weaken the frame and/or repair location.
(14) Using a reciprocating saw or equivalent, cut the fender rail and shotgun at a straight and square section of the hydroform and remove.
(15) Smooth and square the cut edges. (16) Using the damaged structure as a reference cut the service part at the same location as the first cut. Smooth and square the cut edges.
NOTE: The repair structure should butt up to the remaining structure and provide the same overall vehicle geometry.
DR FRAME (Continued)
FRAMES & BUMPERS
13 - 13
1 - HYDROFORM FENDER RAIL 2 - FRONT END SHEET METAL BRACKET 3 - UPPER RADIATOR CROSSMEMBER BOLTS (4)
4 - UPPER RADIATOR CROSSMEMBER 5 - LOWER RADIATOR CROSSMEMBER BOLTS (8) 6 - LOWER RADIATOR CROSSMEMBER
Fig.19HYDROFORMFENDERRAILS
(17) Fabricate 51 mm (2.0 in.) long repair inserts using scrap from the old structure or the replacement part. It will be necessary to split the inserts on each of their four sides to fit into the hydroform.
(18) Remove any paint or e-coat from the inserts and also to the interior and exterior of the hydro- forms. (19) Cut plug weld holes as described below. † On the upper rail, cut one 13 mm (0.5 in.) hole on each side of the rail, 25 mm (1.0 in.) from the butt joint of the tubes. † On the lower rail, cut one 13 mm (0.5 in.) hole on the top and bottom sides of the rail 25 mm (1.0
in.) from the butt joint of the tube. † On the lower rail, cut two 13 mm (0.5 in.) holes on the inner and outer sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.CAUTION: Shield the surrounding area and compo- nents from exposure to the welding spatter and heat.
(20) Install the insert 1” into the replacement part
and tack into place with a weld.
(21) Insert the service part into place and using the appropriate measuring equipment, verify the
front end sheet metal bracket’s location in all three (X,Y, and Z) planes of space. (Fig. 20) (22) Complete all 360° plug welds.
NOTE: Before the final welding, use three dimen- sional measuring equipment to ensure the part is in the correct location. Verify that tap plate extrusion at the bottom of the vertical post lines up with the isolator and hole in the frame perch mount. Also ensure the lower radiator closure tube is bolted into the forward shotgun ends.
(23) Complete welding by making a 360° butt weld
around the fender rails.
(24) Metal finish the exposed welds on the hydro-
forms.
(25) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Inside the rail, inject a creeping wax based rust inhibitor compound to the inside of the hydro- forms ensuring 100% coverage including the mat- ing face between the fender rail sections and insert such that corrosion protection is restored in the internal cavity.
(b) Apply a durable top coat to the outside of the
repair area.
FRAMES & BUMPERS
13 - 14
FRAME (Continued)DR
Fig.20ENGINECOMPARTMENT/FRONTSTRUCTURE
(26) Install the front cab mount bolt if previously
removed and tighten to 81 N·m (60 ft. lbs.).
(27) Install the lower radiator crossmember bolts
and tighten to 28 N·m (21 ft. lbs.).
(28) Install the headlamp unit. (Refer to 8 - ELEC- TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD- LAMP UNIT - INSTALLATION)
(29) Install the upper radiator crossmember. (Refer - BODY/EXTERIOR/UPPER RADIATOR
to CROSSMEMBER - INSTALLATION)
23
(30) Install the wire harness and ground if previ-
ously removed and install the bolts.
(31) Install the integrated power module, if previ- ously removed. (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - INSTALLATION)
(32) Install the air cleaner bracket and air cleaner, if previously removed. (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - INSTALLATION)
(33) Install the radiator assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION)
(34) Install the A/C lines, if previously removed. Refer to the Heating and Air Conditioning section of the manual for the recommended procedures.
(35) Install
the A/C condenser,
if previously removed. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING/A/C CONDENSER - INSTAL- LATION)
(36) Install the fender. (Refer to 23 - BODY/EXTE-
RIOR/FRONT FENDER - INSTALLATION)
(37) Install the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEEL- HOUSE SPLASH SHIELD - INSTALLATION)
(38) Reconnect the battery ground.
DR FRAME (Continued) STANDARD PROCEDURE - REAR FRAME H-SECTION REPLACEMENT
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND- ING OR WELDING METAL, SERIOUS EYE INJURY CAN RESULT. † BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING GRINDING OR WELDING, VERIFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN CONTACT WITH REPAIR AREA, PERSONAL INJURY CAN RESULT. † DO NOT ALLOW OPEN FLAME OR HEAT AND METAL SPATTER FROM ARC WELDING, TO CON- TACT PLASTIC BODY PANELS. FIRE OR EXPLO- SION CAN RESULT. † WHEN WELDED FRAME COMPONENTS ARE REPLACED, ENSURE COMPLETE PENETRATION WELD IS ACHIEVED DURING INSTALLATION. IF NOT, DANGEROUS OPERATING CONDITIONS CAN RESULT. † STAND CLEAR OF CABLES OR CHAINS ON PULLING EQUIPMENT DURING FRAME STRAIGHT- ENING OPERATIONS, PERSONAL INJURY CAN RESULT. † DO NOT VENTURE UNDER A HOISTED VEHI- CLE THAT IS NOT SUPPORTED ON SAFETY STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality of repair would be suspect. Failure to use only pro- duction fasteners or fasteners of equivalent hard- ness can result in loosening or failure. Do not drill holes in top or bottom frame rail flanges, frame rail failure can result. When using heat to straighten frame components do not exceed 566°C (1050°F), metal fatigue can result.
CAUTION: This procedure is designed to replace the H-section/spare tire support located at the rear of the frame assembly. Prior to any cutting, the vehicle must be mounted on the appropriate frame repair equipment (“frame rack”), checked with three dimensional measuring equipment, and the neces- sary pull corrections made. If damage remains in the frame beyond the area covered by this service part after the pull, the frame must be replaced in its entirety.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cargo box. (Refer to 23 - BODY/EX-
TERIOR/CARGO BOX - REMOVAL)
FRAMES & BUMPERS
13 - 15
(3) Remove the trailer hitch. (Refer to 13 - FRAME
BUMPERS/FRAME/TRAILER
HITCH
(4) Raise and support the frame so the tires are off
REMOVAL)
floor.
(5) Remove the shock absorbers. (Refer to 2 - SUS-
PENSION/REAR/SHOCK - REMOVAL)
(6) Remove the rear leaf spring shackle bolts and
let the axle rest on the ground. (Fig. 21)
Fig.21REARSPRING
1 - SPRING SHACKLE 2 - LEAF SPRING EYE BOLT/NUT 3 - REAR LEAF SPRING
(7) Remove the spare wheel. (8) Remove the clip and remove the spare tire
winch tube. (Fig. 22)
Fig.22SPARETIREWINCHTUBE
1 - SPARE TIRE WINCH ASSEMBLY 2 - HAIR PIN CLIP 3 - WINCH TUBE 4 - H-SECTION/SPARE WHEEL SUPPORT
FRAMES & BUMPERS
13 - 16
FRAME (Continued)DR
(9) Remove the bolts and remove the spare tire
winch. (Fig. 23)
(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC- IFICATIONS - FRAME DIMENSIONS)
CAUTION: Shield the surrounding area and compo- nents from exposure to the welding spatter and heat.
(16) Weld the replacement H-section into position. The welding should be performed in a skip (stitch) type method to minimize the heat buildup following I-CAR or the American Welding Society welding pro- cedures and utilizing the process specifications at the end of this section. Refer to the Weld Process Speci- fications welding schedule below.
(17) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Inside the rail, inject a creeping wax based rust inhibitor compound through the existing holes in the frame ensuring 100% coverage including the mating face between the frame and replacement H-section.
(b) Apply a durable top coat to the outside of the
repair area. (18) Position the wiring harness back. (19) Install the spare tire winch and install the
bolts. (Fig. 23)
(20) Tighten the bolts to 41 N·m (30 ft. lbs.). (21) Install the spare tire winch tube and install
the clip. (Fig. 22)
(22) Install the spare tire. (23) Lift the axle into position and install the rear
shackle bolts. (Fig. 21)
(24) Tighten the bolts to 163 N·m (120 ft. lbs.). (25) Install the lower shock absorber bolts. (Refer to 2 - SUSPENSION/REAR/SHOCK - INSTALLA- TION)
(26) Install the trailer hitch. (Refer to 13 - FRAME & BUMPERS/FRAME/TRAILER HITCH - INSTAL- LATION)
(27) Install the cargo box. (Refer to 23 - BODY/EX-
TERIOR/CARGO BOX - INSTALLATION)
(28) Reconnect the battery ground.
Fig.23SPARETIREWINCHASSEMBLY
1 - SPARE TIRE WINCH ASSEMBLY 2 - BOLTS 3 - RETAINER BRACKET 4 - H-SECTION/SPARE WHEEL SUPPORT
(10) Position the wire harness forward of the work
area.
CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in this procedure. The inaccurate and high temperatures achieved during flame or plasma cutting will change the metal char- acteristics and may weaken the frame and/or repair location.
(11) Carefully remove the H-section welds using a
grinder or equivalent tool.
ing welds from the frame.
(12) Remove the H-section and clean any remain-
(13) Trial fit the replacement part. (14) Remove all e-coat from within 25 mm (1.0 in.)
of the weld area.
(15) Using the appropriate measuring equipment, position the replacement part and verify correct posi- tioning in all three (X,Y, and Z) planes of space.
DR FRAME (Continued)
FRAMES & BUMPERS
13 - 17
CAUTION: All welds should conform to DaimlerChrysler vehicle engineering process standard “ps 9472”.
WELD PROCESS SPECIFICATIONS
WELDING PROCESS
FLUX CORED ARC
GAS METAL ARC (MIG)*
SHIELDED METAL ARC
Material Thickness Electrode Type
Electrodes Size Inches Electrode Stick Out Polarity
Shielding Gas
3.7 mm to 4.2 mm
Lincoln Electrical Co. Product #: NR-211 MP (Do Not Substitute)
.045 Tubular 3/89 - 1/29
Electrode 9-9
Work Piece 9+9
Self ShieldedGas Flow Rate Wire Feed Speed (inches per minute)
N/A
110 - 130 Vertical Down 70 - 90 Flat & Overhead
3.7 mm to 4.2 mm
AWS ER70S-3
(Do Not Substitute)
.035 Solid 1/29 - 5/89
Electrode 9+9
Work Piece 9-975% Ar 25% CO2
25 - 35 CFM
245 - 250 Vertical Down
210 - 225 Flat &
Overhead
(STICK)
3.7 mm to 4.2 mm
** AWS E 7018
3/329
N/AElectrode 9+9
Work Piece 9-9
Self ShieldedN/A N/A
Approximate Amperage
Vertical
Flat & Overhead
Voltage Direction of Welding
110 - 130
70 - 90
15 - 18175
15519 - 20
85 (3/329 Diameter) 90 (3/329 Diameter)
N/A
Vertical
Vertical Down Hill (only)
Vertical Down Hill (only)
Vertical - Up Hill (only)
Flat & Overhead
Flat - Push or Drag
Flat - Push or Drag
Flat - Drag
*First choice - Gas Metal Arc Welding Process: Butt joints - apply two layers (passes) of weld metal. First pass should only fill approximately 1⁄2 the thick- ness. Vertical position welds - maintain electrode wire at leading edge of weld puddle while traveling down hill to produce maximum penetration into the sleeve. These techniques work for FCAW as well.
**E7018 new electrodes may be exposed to the atmosphere for up to ten hours with no harmful effect. Reconditioning schedules should come from the manufacturer.
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS
NOTE: Frame dimensions are listed in metric scale. All dimensions are from center to center of Princi- pal Locating Point (PLP), or from center to center of PLP and fastener location.
VEHICLE PREPARATION
Position the vehicle on a level work surface. Using screw or bottle jacks, adjust the vehicle PLP heights to the specified dimension above a level work surface. Vertical dimensions can be taken from the work sur- face to the locations indicated were applicable.
INDEX
DESCRIPTION
FIGURE
Frame Dimensional Graphics, Side And Top View 140.5 In Wheelbase - Heavy Duty - 2 Wheel Drive 140.5 In Wheelbase - Heavy Duty - 4 Wheel Drive 160.5 In Wheelbase - Heavy Duty - 2 Wheel Drive 160.5 In Wheelbase - Heavy Duty - 4 Wheel Drive
24
25
26
27
28
FRAMES & BUMPERS
13 - 18
FRAME (Continued)DR
DR FRAME (Continued)
FRAMES & BUMPERS
13 - 19
FRAMES & BUMPERS
13 - 20
FRAME (Continued)DR
DR FRAME (Continued)
FRAMES & BUMPERS
13 - 21
