Frame - Rivet Replacement
Bulletin No.: 008/97Issued: 04/25/97
Revised:
Category
S
Applicable Model/s
1991-94 Navajo
1994-96 B-Series
Subject:
REPLACING FRAME RIVETS
APPLICABLE MODELS
1991-94 Navajo
1994-96 B-Series
DESCRIPTION
This bulletin contains information on frame rivet replacement. Symptom descriptions, repair procedures, parts and warranty information are also outlined in this bulletin.
NOTE:
Service Managers should make a copy of these procedures and enclose them in section S of the appropriate workshop manual.
SYMPTOMS - This bulletin covers only the symptoms listed below
A. Frame Rivet Replacement - Due to Damaged or Loose Rivets
B. Replacing the Huck Rivet on the Front Frame Area - Due to Noise
NOTE:
Refer to the applicable workshop manual for symptoms not covered in this bulletin.
SYMPTOM A. Frame Rivet Replacement
DESCRIPTION
When damaged or loose rivets are encountered, replace the rivets with the approved service bolts.
CAUTION:
Welding the rivet to the frame is not acceptable.
SERVICE BOLT INSTALLATION
If the rivet requires replacement, install approved service bolts according to the information below.
1. Drill a 3.175 mm (1/8 in.) hole through the loose or damaged rivet.
2. Re-drill the same hole through the shank of the rivet.
^ 10 mm (3/8 in.) Rivets - Drill 8.731 mm (11/32 in.)
^ 11.113 mm (7/16 in.) Rivets - Drill 9.525 mm (3/8 in.)
3. Remove the rivet head with a fiat chisel and hammer (or an air chisel).
4. Drive out rivet with a punch and hammer.
5. Line ream the hole to match the nominal size of the Service bolt with a hole tolerance of +/- 0.127 mm (0.005 in.). Refer to the Parts Information below.
6. Clear the area of any burrs to allow proper seating of bolt head and nut.
7. Select a bolt length that allows at least two (2) threads (minimum) to protrude from the nut when properly torqued. Refer to the Parts Information below.
NOTE:
If the flange nut and bolt are not available, a grade 5 hex nut and bolt with fiat washers under the bolt head and nut may be substituted.
CAUTION:
The following clearances must be present after installation:
^ Minimum of 12.7 mm (1/2 in.) between the bolt and adjacent components except engine and transmission.
^ Minimum clearance between the bolt and the engine and transmission components is 19.05 mm (3/4 in.)
8. Tighten bolts to the specification shown in the Parts Information.
PARTS INFORMATION
WARRANTY INFORMATION
(Applies To Verified Customer Complaints On Vehicles Covered Under Normal Warranty. Refer To The SRT Microfiche For Warranty Term Information.)
SYMPTOM B. Replacing The Huck Rivet On The Front Frame Area Due To Noise
DESCRIPTION
A "snapping" or "popping" noise may be heard from the area where the No. 1 cross-member attaches to the left frame Tail. The noise is evident when driving on rough roads or over bumps. This noise is caused by a loose huck rivet in the lower flange of the frame near the steering gear. Refer to the illustration.
Customers complaining of this problem should have the vehicle inspected and if necessary, have the huck rivet replaced with a nut, bolt and washer assembly.
HUCK RIVET REPLACEMENT
1. Split the exposed collar of the huck rivet with a flat chisel and hammer (or air chisel). Fig. 2
2. Knock the rivet pin out of the blind side with a 1/4 in. (6.35 mm) drift punch and hammer. Fig. 3
3. Cut the rivet head off with a hammer and flat chisel. Fig. 4
4. Knock the sleeve out of the blind side with a 3.8 in, (9.5 mm) drift punch and hammer. Fig. 5
CAUTION:
Do not remove huck rivet with a cutting torch. Using a cutting torch may result in frame damage.
5. Line ream the existing hole through the frame flange, and crossmember to 9/16 in. (14.23 mm).
6. Install a grade 8 nut, bolt and washer (see Parts Information) with the nut and washer on the bottom using the following procedure. Refer to Fig. 6
^ Push the bolt into place using a braze rod to hold the bolt.
^ Position the bolt so that one of the flats face rearward.
^ Slide the bolt into the opening between the front face of the crossmember and the frame liner.
^ Tighten the nut.
Tightening torque: 150 ft-lbs. (203 Nm)
CAUTION:
Do Not weld the nut/washer to the frame.
PARTS INFORMATION
WARRANTY INFORMATION
(Applies To Verified Customer Complaints On Vehicles Covered Under Normal Warranty. Refer To The SRT Microfiche For Warranty Term Information.)
Disclaimer