Dodge dakota 2002 Service Manual page 1680

DR
FRAME (Continued)
(22) Using the appropriate measuring equipment,
verify the front end sheet metal bracket's location in
all three (X,Y, and Z) planes of space, and adjust if
required. (Fig. 15)
Fig. 15 FRAME TIP DIMENSIONS
NOTE:
All measurements are in mm.
1 - PLP POINT
2 - FRAME
3 - PLP POINT
4 - REPLACEMENT FRAME TIP
FRAMES & BUMPERS
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
(23) When correctly fitted and a weld root gap of 4
mm minimum to 6 mm maximum (0.16 in - 0.24 in)
is established, tack the ring fillet welds to hold the
tip in position, then complete the ring fillet welds.
NOTE: Ring-fillet welds may be filled in with weld
material if an improved cosmetic appearance is
desired.
(24) Confirm alignment of the replacement frame
rail tip. (Fig. 15)
(25) Final welding should be performed in a skip
(stitch) type method to minimize the heat buildup
and frame distortion, utilizing the Weld Process
Specifications at the end of this section. The pre-
ferred method is GMAW (MIG).
(a) Apply root pass welds to the root joint one
quadrant at a time, switching to the opposite side
of the frame for each quadrant. (Fig. 9)
(b) Clean the welds of any flux and other impu-
rities before proceeding with the cover pass welds.
(c) Apply the cover pass welds in the same man-
ner as described above.
(26) Confirm alignment of the replacement frame
rail tip. (Fig. 15)
NOTE: Any burned surface coatings will need to be
removed prior to application of corrosion preventa-
tive coatings.
(27) 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 rein-
forcing sleeve.
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