The service assemblies for the left and the right front frame rails are pre-sleeved, mild steel, hydro-formed parts, which correlate directly with the die marks located on the front frame rails. The assemblies include pre-welded support mounting brackets for the body and the radiator.

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Caution: Refer to Collision Sectioning Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



3. Remove all of the related panels and components.



4. Locate the two die-marks on the damaged frame rail. The die marks are located 302 mm (11 7/8 in) rearward from the front frame rail bumper bracket, on the top and bottom side of each rail.




Important: Line up the masking tape with the point of each die mark arrow as shown.

5. Apply masking tape over the die-marks and down each frame rail side as shown, for the cut location.




Important: The tape edge facing the rear of the vehicle is the proper cut location. The cut location is not to exceed 302 mm (11 7/8 in) of the front frame section.

6. Cut the damaged frame rail at the rear edge of the tape line using a reciprocating saw or equivalent, as shown.



7. Remove the damaged frame section.

1. Grind the existing frame rail sectioning location to a 45 degree angle.
2. Prepare all of the attaching surfaces as necessary.



3. Position the service frame section to the existing frame and clamp in place.




Important: Inspect the frame measurements three-dimensionally to ensure proper position of the service frame prior to welding.

4. Continuous-weld the upper and lower horizontal joints from corner to corner.



5. Continuous-weld the inner and outer vertical joints from corner to corner.



6. Clean and prepare all of the welded surfaces.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
8. Install all of the related panels and components.
9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
10. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.