Frame Members-Front Frame Section - Electric: Removal
NOTE:
The following procedure provides steps to replace the front frame short section at the first frame crossmember.
- Restore the vehicle to manufacturer's dimensions.
Refer to: BODY AND FRAME .
- Remove the following items:
- Refer to: Front Bumper - Electric .
- Refer to: Fender .
- Unbolt the Front End Sheet Metal (FESM) body mount bolts and raise or remove the body if required. Refer to: Frame and Body Mounting - Electric .
- Anchor the vehicle to a frame rack following the equipment manufacturer's instructions.NOTE: This section of the frame MUST NOT be straightened if any holes or surfaces show evidence of collapse or buckling. If any evidence of damage exists BEHIND the first frame cross member in terms of buckling, cracking, etc. then the entire front frame section or entire frame must be replaced.
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NOTE: The replacement front frame components are production parts designed with a taper to insert into the front rail section to assist in alignment and welding operations.
Front frame short section overview.
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NOTE: Do not cut directly along the center of the weld line. Leave enough material on the front side of the weld centerline to allow the remaining weld and frame material to be ground back to the front edge of the front mid rail. This is necessary to make sure of correct fit between the frame and the replacement frame section.NOTE: RH side shown, LH side similar.
Locate the vertical weld of the front frame to center rail, using a plasma cutter, reciprocating saw or cut-off wheel cut through the frame rail.Use the General Equipment: GrinderUse the General Equipment: Plasma Cutter
- Remove the frame section from the affected side.
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NOTE: LH side shown, RH side similar.
Grind off the excess welding material that remains around the perimeter of the front edge of the front frame rail of the frame assembly, and remove the remaining portion of the frame section from inside the frame rail.Use the General Equipment: Locking Pliers
- Using a wire brush or sandpaper, remove the e-coat paint from the existing frame near the edges to be welded on the inner and outer surfaces within approximately 15 mm (0.5 in.) of the repair joint.
Frame Weld Nut Repair Process - Battery Attachment
- Overview of locating the nut on the frame assembly.
- Remove the nut welds.Use the General Equipment: Grinder
- Clean the area of the frame bracket surface where the welds were ground.