Dodge ram truck 3500 1996 Service Manual page 1229

mm
FRAME AND BUMPERS 13 - 5
GENERAL INFORMATION (Continued)
• Exhaust system and heat shields.
• Fuel cell and fuel line tubing.
• Front end sheet metal and radiator closure
panel.
• Skid plate.
• Passenger cab.
• Cargo box or bed.
• Spare tire winch.
• Front and rear bumper systems.
S E R V I C E P R O C E D U R E S
FRAME SERVICE
S A F E T Y PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND­
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT, BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER­
IFY THAT VEHICLE F U E L SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE OR EXPLOSION CAN RESULT. WHEN
WELDED FRAME COMPONENTS A R E R E P L A C E D ,
100% PENETRATION WELD MUST BE ACHIEVED
DURING INSTALLATION. IF NOT, DANGEROUS
OPERATING CONDITIONS CAN RESULT. STAND
C L E A R O F C A B L E S OR CHAINS ON PULLING
EQUIPMENT DURING FRAME STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON S A F E T Y STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, qual­
ity of repair would be suspect. Do not drill holes in
top or bottom frame rail flanges, frame rail failure
can result. Do Not use softer than Grade 3 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566°C (1050°F), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566°C (1050°F).
The metal will have a dull red glow at the desired
temperature. Excessive heat will decrease the
strength of the metal and result in a weakened
frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged. The
replacement bolts, nuts and rivets that are used to
join the frame members should conform to the same
specifications as the original bolts, nuts and rivets.
FRAME REPAIRS
DRILLING HOLES
Do not drill holes in frame side rail top and bottom
flanges, metal fatigue can result causing frame fail­
ure. Holes drilled in the side of the frame rail must
be at least 38 mm (1.5 in.) from the top and bottom
flanges.
Additional drill holes should be located away from
existing holes.
WELDING
Use MIG, TIG or arc welding equipment to repair
welded frame components.
Frame components that have been damaged should
be inspected for cracks before returning the vehicle
to use. I f cracks are found in accessible frame com­
ponents perform the following procedures.
(1) Drill a hole at each end of the crack with a 3
mm (0.125 in.) diameter drill bit.
(2) Using a suitable die grinder with 3 inch cut off
wheel, V-groove the crack to allow 100% weld pene­
tration.
(3) Weld the crack.
(4) I f necessary when a side rail is repaired, grind
the weld smooth and install a reinforcement channel
(Fig. 3) over the repaired area.
NOTE: If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches nar­
rower than the side rail flanges. Weld only in the
areas indicated (Fig. 3).
FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
Bolts can be used in place of rivets. When replacing
rivets with bolts, install the next larger size diameter
bolt to assure proper fit. I f necessary, ream the hole
out just enough to sufficiently receive the bolt.
Conical-type washers are preferred over the split-
ring type lock washers. Normally, grade-5 bolts are
adequate for frame repair. Grade-3 bolts or softer
should not be used. Tightening bolts/nuts with the
correct torque, refer to the Introduction Group at the
front of this manual for tightening information.