SPECIFICATION - TORQUE
| DESCRIPTION | N.m | Ft. Lbs. |
|---|---|---|
| Front bumper center bracket nuts | 95 | 70 |
| Front bumper stud plate nuts | 95 | 70 |
| License plate hitch reinforcement bolts | 54 | 40 |
| Rear bumper support bracket stud plate nuts | 54 | 40 |
| Rear bumper support bracket to hitch bolts | 54 | 40 |
| Rear bumper to hitch bolts | 54 | 40 |
SPECIFICATION - FRAME DIMENSIONS
Note. Frame dimensions are listed in metric scale. All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP and fastener location.
| DESCRIPTION | N.m | Ft. Lbs. |
|---|---|---|
| Cab mount bolts | 81 | 60 |
| Cargo box bolts | 108 | 80 |
| Front crossmember bolts - 2WD (light duty only) | 61 | 45 |
| Front crossmember bolts - 2WD (heavy duty only) | 75 | 55 |
| Front crossmember bolts - 4WD (light duty only) | 102 | 75 |
| Front skid plate bolts | 34 | 25 |
| Lower bumper support bracket bolt | 54 | 40 |
| Radiator crossmember bolts - lower | 28 | 21 |
| Radiator crossmember bolts - upper | 28 | 21 |
| Rear crossmember (light duty only) | 102 | 75 |
| Rear crossmember (heavy duty only) | 115 | 85 |
| Rear spring shackle bolts | 163 | 120 |
| Spare tire winch bolts | 41 | 30 |
| Trailer hitch reinforcement bracket bolt | 170 | 125 |
| Transfer Case skid plate bolts | 34 | 25 |
| Transfer Case skid plate crossmember bolts | 34 | 25 |
| Transmission mount to crossmember nuts | 54 | 40 |
TORQUE SPECIFICATIONS
SPECIFICATION - WELDING
| CAUTION | All welds should conform to DaimlerChrysler vehicle engineering process standard "PS 9472". |
| WELDING PROCESS | FLUX CORED ARC | GAS METAL ARC (MIG)* | SHIELDED METAL ARC (STICK) |
|---|---|---|---|
| Material Thickness | 3.7 mm to 4.2 mm | 3.7 mm to 4.2 mm | 3.7 mm to 4.2 mm |
| Electrode Type | Lincoln Electrical Co. Product #: NR-211 MP (Do Not Substitute) | AWS ER70S-3 (Do Not Substitute) | ** AWS E 7018 |
| Electrodes Size Inches | .045 Tubular | .035 Solid | 3/32" |
| Electrode Stick Out | 3/8" - 1/2" | 1/2" - 5/8" | N/A |
| Polarity | Electrode "-" Work Piece "+" | Electrode "+" Work Piece "-" | Electrode "+" Work Piece "-" |
| Shielding Gas | Self Shielded | 75% Ar 25% CO2 | Self Shielded |
| Gas Flow Rate | N/A | 25 - 35 CFM | N/A |
| Wire Feed Speed (inches per minute) | 110 - 130 Vertical Down 70 - 90 Flat & Overhead | 245 - 250 Vertical Down 210 - 225 Flat & Overhead | N/A |
| Approximate Amperage | |||
| Vertical | 110 - 130 | 175 | 85 (3/32" Diameter) |
| Flat & Overhead | 70 - 90 | 155 | 90 (3/32" Diameter) |
| Voltage | 15 - 18 | 19 - 20 | N/A |
| Direction of Welding | |||
| 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 |
WELDING PARAMETERS
*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 thickness. 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.
Scheme 1
Scheme 2
Scheme 3
- Raise and support the vehicle. Refer to «STANDARD PROCEDURE»(ref-303775-S36253149762008103100000) .
- Remove the front skid plate (2 - if equipped). See «REMOVAL»(ref-303885-S01760581572008103100000) .
- On the 2WD models, remove the bolts (2) and remove the crossmember (1).
- On the 4WD models, remove the bolts (1) and remove the crossmember (2).