Removal and Replacement
FRONT FRAME ASSEMBLYWARNINGS AND CAUTIONS
For required warnings and cautions, Refer to Service Precautions.
CAUTION: When removing the section, care should be taken not to damage the side rails where the front frame assembly is attached.
NOTE: The complete front frame assembly includes the front upper frame rails, the crossmember assemblies, and the frame portion ending just in front of the lower dash panel.
The front frame assembly comes complete with all mounts, hardware and bracing to complete the repair.
REMOVAL
1. The frame should be straightened and squared before removing the front frame assembly, Refer to Body and Frame / Specifications / Dimensions.
2. Remove all butt welds at locations where the upper tunnel rails, lower rails, and the side sills attach to the front frame assembly. Use a die grinder or other suitable means.
INSTALLATION
1. Clean and prep all rails and braces.
2. Tack weld new front frame assembly in place using flux core wire.
3. Measure and recheck alignments, Refer to Body and Frame / Specifications / Dimensions.
4. Complete welding, Refer to Welding.
5. Dress the welded area and apply corrosion resistant coatings inside and out.
a. Apply etch-primer to the inside of the frame rail repair area.
b. 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.
c. Apply a durable top coat to the outside of the repair area.