Front Full Frame Sectioning (Light Duty only)
The re-designed frame assembly for the new Pick-Up andUtility Trucks is a mild steel, hydroformed frame assembly. Apre-sleeved replacement front frame service section, consisting ofthe left and right frame rail ends, body, mounting brackets andfront connecting cross tube is available. Replacement bolt-on frontbumper brackets are available and must be orderedseparately.
Warning:Refer toApproved Equipment for Collision Repair Warning.
Warning:Refer toCollision Sectioning Warning.
Note:Perform all of the steps on both of the rails for completemodule replacement.Disable the SIR system. Refer toSIR Disabling and Enabling.Disconnect the negative battery cable. Refer toBattery Negative Cable Disconnection and Connection.Remove all of the related panels and components.
Locate and mark the sectioning location by using at least 2of the measurements below for each frame rail:Top of the frame rail edge rearward 420-mm(16-1/2-in) (with bumper bracketremoved)Bottom of the frame rail edge rearward 387-mm(15-3/16-in) (with bumper bracketremoved)Front edge of the gauge hole forward 22-mm(7/8-in)Center of the gauge hole forward 33-mm(1-1/4)Rear edge of the gauge hole forward 47-mm(1-7/8-in)
Note:Line up the masking tape with the tape edge facing the frontof the vehicle on the sectioning location.Apply masking tape completely around the frame rail next tothe sectioning location as shown.
Note:The tape edge facing the front of the vehicle is the propercut location.Cut each frame rail at the front edge of the tape line usinga reciprocating saw or equivalent, as shown.
Remove the damaged frame section.Installation Procedure
Grind the existing frame rail seam to taper seam at a45-degree angle.Prepare all of the attaching surfaces as necessary.Apply the weld-thru primer to all of the weldedsurfaces.
Position the service frame section to the existing frame andclamp in place.
Note:Verify the frame measurements 3-dimensionally to ensureproper position of the service frame.Continuous-weld the upper and lower horizontal joints threweach corner.Continuous-weld the inner and outer vertical joints fromcorner to corner.
Clean and prepare all of the welded surfaces.Install all of the related panels and components.Connect the negative battery cable. Refer toBattery Negative Cable Disconnection and Connection.Enable the SIR system. Refer toSIR Disabling and Enabling.