GM Service Manual Online
For 1990-2009 cars only

Aligning the frame and leveling the rails may be necessary before you repair the frame.

  1. Remove any equipment that will interfere with access to the crack.
  2. Locate the extreme end of the crack and drill a 6 mm (0.25 in) hole.
  3. V grind the entire length of the crack from the starting point to the 6 mm (0.25 in) at the extreme end.
  4. The bottom of the crack should be opened up 2 mm (1/16 in) in order to allow good penetration of the weld. Use a hacksaw blade.
  5. Weld with the proper electrode and welding techniques.
  6. Grind the weld smooth on the inside and the outside of the rail or crossmember. Be extremely careful to eliminate weld buildup or notches on the edge of the flange.

For more information, refer to Repairing Cracks Description .