Chrysler RAM TRUCK 2500 1994 Service Manual page 937

13 - 24 BUMPERS AND FRAME
•
• Steering gear and linkage.
• Fuel cell and fuel line tubing.
• Front end sheet metal and radiator closure panel.
• Passenger cab.
• Cargo box or bed.
• Front and rear bumper systems.
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. Gas welding is not recom­
mended. Gas welding transmits excessive heat to
frame components causing possible metal fatigue.
Frame components that have been damages should
be inspected for cracks before returning the vehicle
to use. If 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) If necessary when a side rail is repaired, grind
the weld smooth and install a reinforcement channel
(Fig. 3) over the repaired area.
If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches
narrower than the side rail flanges. Weld only
i n the areas indicated (Fig. 3).
Fig. 3 Frame Reinforcement
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. If 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.
FRAME DIMENSIONS
Frame dimensions are listed in inch scale. All di­
mensions are from center to center of Principal Lo­
cating Point (PLP), or from center to center of PLP
and fastener location.
VEHICLE PREPARATION
Position the vehicle on a level work surface. Using
screw or bottle jacks, adjust the vehicle PLP heights
to the specified dimension above a level work surface.
Vertical dimensions can be taken from the work sur­
face to the locations indicated (Fig. 4, 5, 6 or 7).