Frame: Service and Repair

Frame Members

General Equipment
3 Phase Inverter Spot Welder 254-00002
Compuspot 700F Welder 190-50080
I4 Inverter Spot Welder 254-00014
Inverter Welder with MIG Welder 254-00015







WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

1. WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if damaged. Prior to replacement of frame rail crush zones, straighten damaged frame rails to correct frame dimensions. Failure to follow these instructions may adversely affect frame rail crush zone performance and may result in serious personal injury to vehicle occupants in a crash.

Position the vehicle on a frame repair rack following the manufacturer's recommendations. Measure the vehicle to determine if the body requires rough straightening and alignment. For dimensional information, refer to Body.

2. Remove the hood.
3. Remove the battery.
4. Remove the front bumper cover.
5. Remove the fender(s) from the affected side(s).

6. Remove the front crossmember assembly.
- Remove the crossmember bolts.







7. Remove the radiator grille opening panel reinforcement.
8. Using a reciprocating saw, plasma cutter or die grinder with a cutting disc, cut through the complete cross section of the outer side member.
- Preliminary outer member cut location







9. Using a reciprocating saw, plasma cutter or die grinder with a cutting disc, cut through the complete cross section of the inner side member.
1. Cut location
2. Drill out the spot welds







10. Prepare the replacement section of the frame member.
- Cut the replacement section to equal the portion of the original frame member removed.

11. Clamp the service replacement section in position.
- Continuous Metal Inert Gas (MIG) weld the outer frame member







12. Weld the inner portion of the frame member.
1. Continuous MIG weld.
2. Resistance spot weld.







13. Install the crossmember mount bracket.
- Resistance spot weld.







14. Resistance spot weld locations as shown.







15. Install the crossmember.
16. Install the radiator grille opening panel reinforcement.
17. Install the battery.
18. Install the hood.
19. Install the fender(s) from the affected side(s).
20. Install the front bumper cover.

Removal and Installation

Front Side Member and Fender Apron Panel

NOTE: Left side shown, right side similar.







WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.

1. WARNING: Frame rail crush zones absorb crash energy during a collision and must be replaced if damaged. Prior to replacement of frame rail crush zones, straighten damaged frame rails to correct frame dimensions. Failure to follow these instructions may adversely affect frame rail crush zone performance and may result in serious personal injury to vehicle occupants in a crash.

Position the vehicle on a frame repair rack following the manufacturer's recommendations. Measure the vehicle to determine if the body requires rough straightening and alignment. For dimensional information, refer to Body.

2. Remove the hood.
3. Remove the fender(s) from the affected side(s).
4. Remove the door.
5. Remove the cowl panel and body lock carrier.
6. Using a reciprocating saw, plasma cutter or die grinder with cutting disc cut the fender apron as indicated.
- Preliminary cut location







7. Drill out the spot welds.
1. Drill out the spot welds (single panel thickness).
2. Drill out the spot welds (2 panel thicknesses).







8. Prepare the replacement fender panel for installation.
- Drill 10 mm (0.393 in) diameter holes for puddle welding.







9. Clamp the panel in place and weld.
1. Resistance spot weld.
2. Puddle weld.







10. Apply corrosion protection to the repair area as required. For additional information, refer to Restoring Corrosion Protection Following Repair.
11. Install the cowl panel and lock carrier.
12. Install the fender(s) from the affected side(s).
13. Install the hood.
14. Install the door.