The re-designed frame assembly for the new S/T Utility is a mild, steel hydroformed frame assembly. A front frame service section consisting of the left and right frame ends, body, and radiator support mounting brackets and front connecting cross tube is available. If damage permits, locate and cut off the front 420 mm (16½ in) portion of the frame using the die-mark indicators as a guide. The front and rear body mounts, radiator support mounts, steering gear and transmission cross-member can be ordered and replaced separately.

1. Remove all of the related panels and components including the front bumper assembly.



2. Locate the 2 die-marks on each frame. The die marks are located 420 mm (16½ in) rearward from each front frame rail end on the top and bottom side of each rail.




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

3. 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 420 mm (16½ in) of the front frame section.

4. Cut each frame at the rear edge of the tape line using a reciprocating saw or equivalent, as shown.



5. Remove the damaged frame section.

1. Grind the existing frame rail seam to taper seam at a 45 degree angle.
2. Prepare all of the attaching surfaces as necessary.
3. Apply the weld-thru primer to all of the welded surfaces.



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




Important: Verify the frame measurements 3-dimensionally to ensure proper position of the service frame.

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




Important: Verify the frame measurements 3-dimensionally to ensure proper position of the service frame.

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



7. Clean and prepare all of the welded surfaces.
8. Install all of the related panels and components.