Front Frame Rail Tip Replacement

CAUTION: This procedure is designed to replace the front frame rail tips that have been damaged in the crush initiator zones. Prior to any cutting, the vehicle must be mounted on the appropriate frame repair equipment ("frame rack"), checked with three dimensional measuring equipment, and the necessary pull corrections made without the use of heat. (Refer to FRAME & BUMPERS/FRAME - SPECIFICATIONS - FRAME DIMENSION )

• If damage remains in the frame beyond the area covered by this service part after the pull, the frame must be replaced in its entirety.
• If damage to the front body structure is evident, repair the Front End Sheet Metal (FESM) fender rails as necessary. (Refer to FRAME & BUMPERS/FRAME - STANDARD PROCEDURE - HYDROFORM FENDER RAIL REPAIR )
• Inspect all body mount bolts for damage and repair if necessary. (Refer to EXTERIOR/BODY ISOLATORS - REMOVAL & /INSTALLATION )

CAUTION: Inspect the tire winch assembly for damage. If any one or more of the following are evident, replace the winch assembly.

• Indications of cracked or bulging plastic.
• Housing flanges are bent or cracked.
• If winch was loose before repair.
• If the rivet heads are separated from the housing in any way.

Fig 1: Locating Battery Negative Cable

Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

1. Before proceeding with this repair procedure review the required service warnings and precautions. (Refer to FRAME & BUMPERS/FRAME - WARNING )
2. Disconnect and isolate the battery negative cable (4).
   Fig 2: Identifying Front Fender Liner

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3. Remove the front fender liner of the side being serviced. (Refer to EXTERIOR/LINER - FRONT FENDER ).
   Fig 3: Removing/Installing Front Fascia Support

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4. Remove the front fascia support (4). (Refer to FRAME & BUMPERS/BUMPERS/SUPPORT-FRONT FASCIA - REMOVAL )
5. Remove the washer bottle and coolant recover bottles, if required.
   Fig 4: Identifying Radiator

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6. Remove the radiator and lower radiator hose. Refer to RADIATOR .
   Fig 5: Identifying Sway Bar And Mounting Bracket Bolts

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7. Remove the sway bar mounting bracket bolts (1) and position the sway bar (2) out of the way.
   Fig 6: Identifying Power Steering Hoses And Axle Vent Hose

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8. For left side frame rail tips, position the power steering hoses (2) and axle vent hose (1), out of the way.
   Fig 7: Identifying Toe Hook, Front Structure Mount Bolt And Bumper Support Nuts

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9. Remove the front structure mount bolt (3) to the Front End Sheet Metal (FESM) bracket and the lower bumper support nuts (1) attaching the tow hook (5), if equipped.
   Fig 8: Cutting And Removing Damaged Frame Rail Tip Behind Stop Bracket

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   CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in the next step. This is due to the inaccurate nature of the cut-line and the fact that the high temperatures achieved during the flame or plasma cutting will change the metal characteristics and may weaken the frame and/or repair location.
10. Using a reciprocating saw (2) or equivalent, carefully cut and remove the damaged frame rail tip behind the stop bracket (1).
    Fig 9: Identifying Three Puddle Welds Attaching Remaining Frame Tip Section To Frame

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11. Remove the three puddle welds attaching the remaining frame tip section (2) to the frame (1) at the locations indicated. (Right side shown in illustration, left side similar.)
    Fig 10: Cutting Along Edge Of Weld

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12. Remove the welds (4) by cutting along the outside edge of the weld (1) approximately 1/8 in. (2) using a plasma cutter or drilling out and then using a grinder to remove the welds.
    CAUTION: Oxyacetylene cutting torches or equivalent flame sources should never be used for cutting or welding. Only non-flame cutting methods should be used unless specified otherwise.
    Fig 11: Identifying Puddle Weld And Frame Tip

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13. With the puddle welds (1) removed, remove the remaining piece of the frame tip (2) from within the frame rail and discard.
14. Smooth and square the cut edges of the original frame.
15. Remove any burrs at the holes (1) and frame edges.
    Fig 12: Dry Fitting New Rail To Verify Alignment

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16. Dry fit the new rail (2) to verify alignment, fit and make any adjustments as necessary.
17. Remove all internal and external OEM e-coat within 25 mm (1.0 in.) of the weld joint on the replacement tip and the existing frame rail.
    Fig 13: Identifying Toe Hook, Front Structure Mount Bolt And Bumper Support Nuts

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    NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventative coatings.
    CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
18. Loosely install the lower FESM insulator and front structure mounting bolt (3).
    Fig 14: Identifying Stop Bracket And Frame Rail

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19. Position the stop bracket (2) against the frame rail (1).
    Fig 15: Verifying Front End Sheet Metal Bracket Locations

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20. Using the appropriate measuring equipment, verify the front end sheet metal bracket's location in all three (X, Y, and Z) planes of space, and adjust if required. (Refer to FRAME & BUMPERS/FRAME - SPECIFICATIONS - FRAME DIMENSION )
    CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
    Fig 16: Identifying Upper Ring Fillet Welds

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21. When correctly fitted, tack the three upper ring fillet welds (1) to hold the tip (3) in position, then complete the ring fillet welds (1).
    NOTE: Ring-fillet welds may be filled in with weld material if an improved cosmetic appearance is desired.
22. Confirm alignment of the replacement frame rail tip.
23. Final welding should be performed in a skip (stitch) type method to minimize the heat buildup and frame distortion, utilizing the SPECIFICATIONS - WELD PROCESS . The preferred method is GMAW (MIG). (Refer to FRAME & BUMPERS/FRAME - SPECIFICATIONS - WELDING )
    1. Apply root pass welds to the root joint (5) behind the stop bracket (2), one quadrant at a time, switching to the opposite side of the frame for each quadrant.
    2. Apply root pass welds to the root joint in front (4) of the stop bracket (2), one quadrant at a time, switching to the opposite side of the frame for each quadrant.
    3. Clean the welds of any flux and other impurities before proceeding with the cover pass welds.
    4. Apply the cover pass welds in the same manner as described above.
24. Confirm alignment of the replacement frame rail tip.
    NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventative coatings.
25. Dress the welded area and apply corrosion resistant coatings inside and out.
    1. Apply etch-primer to the inside of the frame rail repair area.
    2. Inside the rail, inject a creeping wax based rust inhibitor compound through the existing holes in the frame ensuring 100% coverage including the space between the original frame rail and the reinforcing sleeve.
    3. Apply a durable top coat to the outside of the repair area.
       Fig 17: Identifying Toe Hook, Front Structure Mount Bolt And Bumper Support Nuts

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26. Install the tow hook assembly (5), if equipped, and install the two lower fascia support nuts (1).
27. Tighten the nuts (1) to 95 N.m (70 ft. lbs.).
28. Install the front body mount bolt (3) and tighten to 81 N.m (60 ft. lbs.).
    Fig 18: Removing/Installing Front Fascia Support

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29. Install the front fascia support (4). (Refer to FRAME & BUMPERS/BUMPERS/SUPPORT-FRONT FASCIA - INSTALLATION )
    Fig 19: Identifying Stabilizer Bar And Support Bracket Bolts

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30. Position the stabilizer bar (2) back and install the support bracket bolts (1).
31. Tighten the bracket bolts (1) to the frame to 61 N.m (45 ft. lbs.).
    Fig 20: Identifying Power Steering Lines And Axle Vent Tube

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32. Position the power steering lines (2) and the axle vent tube (1) back into position, if necessary.
    Fig 21: Identifying Radiator

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33. Install the radiator and lower radiator hose. Refer to RADIATOR .
    Fig 22: Identifying Front Fender Liner

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34. Install the front wheelhouse splash shield. (Refer to EXTERIOR/LINER - FRONT FENDER )
    Fig 23: Locating Battery Negative Cable

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35. Connect the negative battery cable (4).