Dodge dakota 2002 Service Manual page 1684

DR
FRAME (Continued)
1 - HYDROFORM FENDER RAIL
2 - FRONT END SHEET METAL BRACKET
3 - UPPER RADIATOR CROSSMEMBER BOLTS (4)
(17) Fabricate 51 mm (2.0 in.) long repair inserts
using scrap from the old structure or the replacement
part. It will be necessary to split the inserts on each
of their four sides to fit into the hydroform.
(18) Remove any paint or e-coat from the inserts
and also to the interior and exterior of the hydro-
forms.
(19) Cut plug weld holes as described below.
• On the upper rail, cut one 13 mm (0.5 in.) hole
on each side of the rail, 25 mm (1.0 in.) from the butt
joint of the tubes.
• On the lower rail, cut one 13 mm (0.5 in.) hole
on the top and bottom sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.
• On the lower rail, cut two 13 mm (0.5 in.) holes
on the inner and outer sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
(20) Install the insert 1" into the replacement part
and tack into place with a weld.
(21) Insert the service part into place and using
the appropriate measuring equipment, verify the
Fig. 19 HYDROFORM FENDER RAILS
4 - UPPER RADIATOR CROSSMEMBER
5 - LOWER RADIATOR CROSSMEMBER BOLTS (8)
6 - LOWER RADIATOR CROSSMEMBER
front end sheet metal bracket's location in all three
(X,Y, and Z) planes of space. (Fig. 20)
NOTE: Before the final welding, use three dimen-
sional measuring equipment to ensure the part is in
the correct location. Verify that tap plate extrusion
at the bottom of the vertical post lines up with the
isolator and hole in the frame perch mount. Also
ensure the lower radiator closure tube is bolted into
the forward shotgun ends.
around the fender rails.
forms.
resistant coatings inside and out.
FRAMES & BUMPERS
(22) Complete all 360° plug welds.
(23) Complete welding by making a 360° butt weld
(24) Metal finish the exposed welds on the hydro-
(25) Dress the welded area and apply corrosion
(a) Inside the rail, inject a creeping wax based
rust inhibitor compound to the inside of the hydro-
forms ensuring 100% coverage including the mat-
ing face between the fender rail sections and insert
such that corrosion protection is restored in the
internal cavity.
(b) Apply a durable top coat to the outside of the
repair area.
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