GM Service Manual Online
For 1990-2009 cars only

Using improper welding techniques causes many weld and/or frame failures. The following information points out potential areas of difficulty and provides general guidelines for successful frame welding:

    • Most weld failures occur at the end of the weld in areas of the frame under high stress.
    • Eliminate the ends of the weld by making a hole or slot in the part to be attached .
    • Use a fillet weld around the slot or plug weld.
    • Do not leave a notch at the end of a weld.
    • Do not overweld, especially areas of the frame that receive high concentrations of stress.
    • Weld small cracks in a crossmember. Refer to Repairing Cracks Description .