LIGHT DUTY FRONT FRAME RAIL TIP REPLACEMENT
| 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 necessary pull corrections made without the use of heat. See SPECIFICATIONS . 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. If damage to the front body structure is evident, repair the Front End Sheet Metal (FESM) fender rails as necessary. See STANDARD PROCEDURE . Inspect all body mount bolts for damage and repair if necessary. Refer to REMOVAL . |
| CAUTION | Inspect the spare tire winch assembly for damage. If any one or more of the following are evident, replace the winch assembly. Indications of cracked or bulging plastic. Housing flanges are bent or cracked. If winch was loose before repair. If the rivet heads are separated from the housing in any way. |
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- Before proceeding with this repair procedure review the required service warnings and precautions. See «WARNING»(ref-303885-S27407660032008103100000) .
- Disconnect and isolate the battery negative cable.
- Remove the front wheelhouse splash shield. Refer to «REMOVAL»(ref-303774-S09297323782008103100000) .
- Remove the bolts and position aside the wire harness and grounds, if required.
- Remove the front bumper. See «REMOVAL»(ref-303885-S00822757802008103100000) .
- Loosen and lower the stabilizer bar mount and bar. Refer to «REMOVAL»(ref-303782-S23405788342008103100000) .
- Remove the bolt from the front cab mount (2) to the Front End Sheet Metal (FESM) bracket. 1 - Item_1 2 - Item _2 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 characteristics and may weaken the frame and/or repair location.
- Using a reciprocating saw or equivalent tool, carefully cut and remove the damaged frame rail tip (2). Cut at the forward edge of the weld at the tip to frame joint (1); do not cut the main frame rail 1 - Item_1 2 - Item _2
- Using a plasma cutter, remove the puddle weld (3) that attaches the frame tip to the frame rail. (Left side shown, Right similar.)
- With the puddle weld removed, grind any remaining weld and remove the remaining piece of the frame tip (1) from within the frame rail and discard.
- Smooth and square the cut edges of the original frame.
- Remove any burrs at the hole and frame edge CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
- Dry fit the new rail to verify alignment and make any adjustments as necessary
- Remove all internal and external OEM e-coat within 25 mm (1.0 in.) of the weld joint on the replacement tip and the existing frame rail
- When correctly aligned, tack weld the new rail tip into place
- Confirm that the alignment of the replacement frame rail tip is within specifications. See «SPECIFICATIONS»(ref-303885-S26237721962008103100000) .
- Apply ring-fillet weld (3) into the ring-fillet weld hole on the replacement frame tip
- Start the ring-fillet welds at location (1) and follow around the circumference of the ring-fillet weld hole and end weld overlapping start point (2) 1 - Item_1 2 - Item _2
- Welding at the tip to frame joint (1) should be performed in a skip (stitch) type method to minimize the heat buildup and frame distortion, utilizing the Weld Process Specifications. See «SPECIFICATIONS»(ref-303885-S26237721962008103100000) .
- Apply root pass welds to the joint, one quadrant at a time, switching to the opposite side of the frame rail for each quadrant.
- Clean the welds of any flux and other impurities before proceeding with the cover pass welds
- Apply the cover pass welds in the same manner as described above
- Confirm alignment of the replacement frame rail tip. See «SPECIFICATIONS»(ref-303885-S26237721962008103100000) . NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventative coatings.
- Dress the welded area and apply corrosion resistant coatings inside and out. Apply etch-primer to the inside of the frame rail repair area. 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 reinforcing sleeve. Apply a durable top coat to the outside of the repair area.
- Tighten bolt at the front cab mount (2) to the FESM bracket to 81 N.m (60 ft. lbs.).
- Install and tighten the stabilizer bar. Refer to «INSTALLATION»(ref-303782-S12795746152008103100000) .
- Install the front bumper. See «INSTALLATION»(ref-303885-S36715666412008103100000) .
- Install wire harness and grounds as necessary.
- Install the front wheelhouse splash shield. Refer to «REMOVAL»(ref-303774-S09297323782008103100000) .
- Reconnect and isolate the battery negative cable.
