Frame Repair Crack Repair

Repair cracks separately when cracks occur the rail and reinforcement at a particular area of the frame. The flanges react independently to prevent localized stress concentration. Use a copper spacer between the flanges of cracked base rail flanges and reinforcement flanges.

Use a weld bead to provide a good, smooth radius when repairing crossmember mounting flange cracks. Replace any damaged crossmember.

Align the frame and level the rails before repairing the frame:

1. Remove any equipment that interferes with access to the crack.
2. Locate the extreme end of the crack and drill a 3 mm (0.12 in) hole.
3. V grind the entire length of the crack from the starting point to the 3 mm (0.12 in) hole at the extreme end.
4. Remove the protective coating on the frame in the area of the repair. Open the bottom of the crack 2 mm (1/16 in) to allow good penetration of the weld. Use a hacksaw blade.
5. Weld the frame with the proper electrode and the proper welding techniques. Refer to Welding Description Welding Description .
6. Grind the weld smoothly on the inside and the outside of the rail or the crossmember. Eliminate the weld buildup or notches on the edge of the flange. Apply the coating of protective material.

Frame Repair Welding Repair

Perform the following steps when welding:

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery.
2. The frame is covered with a protective wax coating.

-	Use a wire brush to remove any concentration of wax before welding.

-	Apply a new wax coating when done welding.

3. Do not use oxyacetylene welding equipment.
4. Use electrodes with a smaller diameter.

Make several passes. Do not make any more passes than necessary.

5. Only use as much heat as is necessary to achieve adequate penetration.
6. Make sure that the weld is free from craters and undercuts.
7. Remove the scale from each successive pass.
8. Grind the surface of the weld flush with the parent material when repairing a crack.
9. Do not weld across the flanges when mounting any accessories.
10. Do not weld within 19 mm (0.75 in) of a flange when mounting any accessories.
11. Leave at least 6 mm (0.23 in) between the end of a weld and the edge of the part.
12. Do not weld the cast brackets to the frame.
13. Do not weld together the flanges of any cracked reinforcements and base rails.
14. Do not attach the ground cable to the engine. Connect the welding machine ground cables as close to the working area as possible.
15. Keep the welding cables away from the vehicle wiring. Avoid any direct contact between the welding cables and any part of the vehicle.