WARNING - FRAME REPAIR
| WARNING | Before performing any welding operations disconnect and isolate the battery negative (ground) cable and disconnect all wire harness connectors from the Occupant Restraint Controller (ORC). Failure to take the proper precautions could result in accidental airbag deployment and other possible damage to the supplemental restraint system circuits and components. Use eye protection when grinding 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 contact plastic body panels. Fire or explosion 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 straightening operations, personal injury can result. Do not venture under a hoisted vehicle that is not supported on safety stands, personal injury can result. No heat may be used if frame straightening is required. The use of heat is acceptable in those situations where the part being heated will be replaced. Failure to follow these instructions may result in personal injury. |
| CAUTION | Do not reuse damaged fasteners, quality of repair would be suspect. Failure to use only production fasteners or fasteners of equivalent hardness can result in loosening or failure. Do not drill any holes in the frame that are not specifically outlined in this or other, DaimlerChrysler procedure as frame rail failure can result. |
FRAME DIMENSION
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.
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 surface to the locations indicated were applicable.
| DESCRIPTION | FIGURE |
|---|---|
| FRAME DIMENSIONS (PLAN VIEW) | (Scheme 44). |
| FRAME DIMENSIONS (SIDE VIEW) | (Scheme 45). |
INDEX
Scheme 44
Scheme 45
WELDING
| CAUTION | All welds should conform to DaimlerChrysler vehicle engineering process standard "PS 9472". |
| WELDING PROCESS | *FLUX CORED ARC | GAS METAL (MIG) ARC | SHIELDED METAL ARC (STICK) | |
|---|---|---|---|---|
| Material Thickness | 1.80 mm | 1.80 mm | 1.80 mm | 1.80 mm |
| Electrode Type | Lincoln Electric Co. Product No. NP-211 MP | Lincoln Electric Co. Product No. NP-211 MP (Do Not Substitute) | AWS ER70S-3 (Do Not Substitute) | AWS E 7018 |
| Electrodes Size Inches | .035 Tubular | .045 Tubular | .035 Solid | 3/32 |
| Polarity | 3/8" | 3/8" - 1/2" | 1/2" - 5/8" | N/A |
| Shielding Gas | Electrode "-" Work Piece "+" | Electrode "-" Work Piece "+" | Electrode "+" Work Piece "-" | Electrode "+" Work Piece "-" |
| Gas Flow Rate | N/A | N/A | 75% Ar 25 - 35 CFH | N/A |
| Wire Feed Speed (inches per minute) | 90 - 110 Vertical Down 60 - 70 Flat & Horizontal | 110 - 130 Vertical Down 70 - 90 Flat & Overhead | 245 - 250 Vertical Down 210 - 225 Flat & Overhead | N/A |
| Approximate Amperage | ||||
| Vertical | 110 - 120 | 160 - 170 | 175 | 85 (3/32 Dia.) |
| Flat & Overhead | 50 - 60 | 120 - 140 | 155 | 90 (3/32 Dia.) |
| Voltage | 15 - 16 | 15 - 18 | 19 - 20 | |
| Direction of Welding | ||||
| Vertical | Vertical Down Hill (only) | Vertical Down Hill (only) | Vertical Down Hill (only) | Vertical Up Hill (only) |
| Flat & Overhead | Flat - Push or Drag | Flat - Push or Drag | Flat - Push or Drag | Flat - Drag |
WELDING PARAMETERS
*First choice - Flux Cored Arc Welding Process: Butt joints - Vertical position welds - maintain end of electrode wire at leading edge of weld puddle while traveling down hill to produce maximum penetration into sleeve. This technique works for Gas Metal Arc (MIG) as well.
Note. If MIG welding process is selected the galvanized coating must be removed from both sides of the material adjacent to the weld joint.