Dodge ZB 2005 Service Manual page 761

13 - 10 FRAME & BUMPERS
FRAME (Continued)
The frame is constructed with mild and high
strength low alloy steel tubing. The frame is held
rigid by cross braces and stringers. The datum plane
is defined by the bottom of the frame rails under the
two front shock towers and at the rear of the frame
just aft of the differential at the center of the 1 in. by
2 in. crossbeam. The left front PLP is the master
gauge location to hold the frame in position during
production welding. The left rear PLP is used to
locate side to side position. All frame measurements
taken during collision repair should begin at the left
front PLP. If the left front frame has been damaged,
the PLP can be repositioned by taking measurements
from undamaged suspension pivot locations or net
form and pierce points. Even though the front frame
rail vertical height will vary from side to side, the
center of the lower control arm and upper shock
mounting holes must be located equally from side to
side above the datum line. (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - FRAME
DIMENSIONS)
FRONT FRAME ASSEMBLY
WARNINGS AND CAUTIONS
For required warnings and cautions, (Refer to 13 -
FRAME & BUMPERS/FRAME - WARNING).
CAUTION: When removing the section, care should
be taken not to damage the side rails where the
front frame assembly is attached.
NOTE: The complete front frame assembly includes
the front upper frame rails, the crossmember
assemblies, and the frame portion ending just in
front of the lower dash panel.
The front frame assembly comes complete with all
mounts, hardware and bracing to complete the
repair.
Removal
(1) The frame should be straightened and squared
before removing the front frame assembly (Refer to
13 - FRAME & BUMPERS/FRAME - SPECIFICA-
TIONS - FRAME DIMENSIONS).
(2) Remove all butt welds at locations where the
upper tunnel rails, lower rails, and the side sills
attach to the front frame assembly. Use a die grinder
or other suitable means.
Installation
(1) Clean and prep all rails and braces.
(2) Tack weld new front frame assembly in place
using flux core wire (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - WELD-
ING).
(3) Measure and recheck alignments (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECIFICATIONS -
FRAME DIMENSIONS).
(4) Complete welding (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - WELD-
ING).
(5) 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.
(c) Apply a durable top coat to the outside of the
repair area.
FRONT UPPER FRAME RAIL ASSEMBLY
WARNINGS AND CAUTIONS
For required warnings and cautions, (Refer to 13 -
FRAME & BUMPERS/FRAME - WARNING).
NOTE: The front upper frame rails and cross sup-
port are serviced as a complete assembly.
• All or a portion of the replacement assembly
may be used depending on the extent of damage.
• This assembly will have to be sectioned into
the vehicle frame.
• Follow recommended I-CAR repair procedures
for sectioning of frame and body panels.
Removal
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. This
is due to the inaccurate nature of the cut-line and
the fact that the high temperatures achieved during
flame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.
CAUTION: Do not reuse damaged fasteners; quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
any holes in the frame that are not specifically out-
lined in this or any other DaimlerChrysler proce-
dure, as frame rail failure can result. When using
heat to straighten frame components do not exceed
566°C (1050°F); metal fatigue can result.
ZB