Frame Repairs: Welding

Use MIG, TIG or arc welding equipment to repair welded frame components.

Frame components that have been damaged should be inspected for cracks before returning the vehicle to use. If cracks are found in accessible frame components perform the following procedures.

Drill a hole at each end of the crack with a 3 mm (0.125 in.) diameter drill bit.
Using a suitable die grinder with 3 inch cut off wheel, V-groove the crack to allow 100% weld penetration.
Weld the crack.
If necessary when a side rail is repaired, grind the weld smooth and install a reinforcement channel over the repaired area. See Fig 1.

CAUTION: A reinforcement should never be used on the front section of the frame. The frame section forward of the suspension mounts contains energy management holes. See Fig 2. Reinforcing this area may effect energy management.

NOTE: If a reinforcement is required, it should completely cover the repaired area. The reinforcement should also overlap the top and bottom of the frame by more than 50% of its width. Weld as indicated. See Fig 1.

Fig 1: FRAME REINFORCEMENT

Courtesy of DAIMLERCHRYSLER CORP.

1 - FRAME CENTER LINE

2 - FRAME

3 - FRAME REPAIR REINFORCEMENT

Fig 2: ENERGY MANAGEMENT HOLES

Courtesy of DAIMLERCHRYSLER CORP.

1 - ENERGY MANAGEMENT HOLES