Body and Frame: Service Precautions

WELDING PRECAUTIONS - STEEL

The correct equipment and settings must be used when welding mild- or high-strength steel. MIG and resistance spot welding are the preferred methods. Surfaces must be clean and free of foreign materials.

- Correct eye protection must be worn.
- The correct protective clothing should always be worn.
- Adequate ventilation must be provided to avoid accumulation of poisonous gases.
- A test weld should always be carried out on a test sample.
- Use cleaning brushes and abrasive grinding wheels dedicated to the type of materials being welded.
- Follow equipment manufacturer's prescribed procedures and equipment settings for the type of welder being used. ER70S-2 or ER70S-6 wire are typically used for MIG welding steel.
- Disconnect the battery ground cable.
- Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
- Corrosion protection must be restored whenever bare metal repairs are made.
- Adequate power supply needs to be used to make sure of correct equipment performance.
- Factory spot welds may be substituted with either resistance spot welds or MIG plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
- Vehicles equipped with optional safety canopy require removal of these components prior to any welding procedures being carried out in the roof-line or body side areas of the vehicle. Refer to Restraint Systems &/or Air Bag Systems.

Welding Precautions - Dual-Phase Steel
The correct equipment and settings must be used when welding dual-phase steel. MIG and resistance spot welding are the recommended methods. Surfaces must be clean and free of foreign materials.

ER70-S-6 is the recommended wire specification to use when welding dual-phase steel components.
Recommended gas mixtures are as follows: CO2, 92Ar8CO2, 84Ar16CO2 and 77Ar23CO2.
Components made of dual-phase steel should not be heated to straighten or repair. New components should be installed if severely bent or kinked.

Do not use Oxyacetylene equipment to weld dual-phase steel.

- Correct eye protection must be worn.
- The correct protective clothing should always be worn.
- Adequate ventilation must be provided to avoid the accumulation of poisonous gases.
- A test weld should always be carried out on a test sample.
- Use cleaning brushes and abrasive grinding wheels dedicated to the type of materials being welded.
- Follow equipment manufacturer's prescribed procedures and equipment settings for the type of welder being used.
- Disconnect the battery ground cable.
- Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
- Corrosion protection must be restored whenever bare metal repairs are made.
- Adequate power supply needs to be used to make sure of correct equipment performance.
- Factory spot welds may be substituted with either resistance spot welds or MIG plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
- Vehicles equipped with optional safety canopy require removal of these components prior to any welding procedures being carried out in the roof-line or body side areas of the vehicle. Refer to Restraint Systems &/or Air Bag Systems.