Jeep Wrangler TJ. Manual — part 458
INSTALLATION
(1) Position the bumper on the vehicle.
(2) Install the nuts attaching the bumper to the
rear frame crossmember and tighten to 77 N·m (57
ft. lbs.).
(3) If equipped, install the rear tow eye/hook.
(Refer to 13 - FRAME & BUMPERS/FRAME/REAR
TOW HOOK - INSTALLATION)
(4) Install the bolt attaching the bumper to frame
rail and tighten to 77 N·m (57 ft. lbs.).
(5) Connect the rear fog lamp electrical connectors,
if equipped.
FRAME
STANDARD PROCEDURE - FRAME SERVICE
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER-
IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE
OR
EXPLOSION
CAN
RESULT.
WHEN
WELDED FRAME COMPONENTS ARE REPLACED,
100% PENETRATION WELD MUST BE ACHIEVED
DURING
INSTALLATION.
IF
NOT,
DANGEROUS
OPERATING CONDITIONS CAN RESULT. STAND
CLEAR OF CABLES OR CHAINS ON PULLING
EQUIPMENT
DURING
FRAME
STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 3 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566°C (1050°F), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
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 the top and bottom of frame
rail, metal fatigue can result causing frame failure.
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.
Fig. 3 REAR BUMPER COMPONENTS
1 - BODY
2 - CROSSMEMBER
3 - FRAME
4 - REAR BUMPER
5 - REAR BUMPER
6 - BRACE
7 - REAR BUMPER EXTENSION
TJ
FRAME & BUMPERS
13 - 3
REAR BUMPER (Continued)
Frame components that have been damaged 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 (O.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. 4) over the repaired area.
CAUTION: A reinforcement should never be used on
the front section of the frame. The frame section
forward of the suspension mounts contains energy
management holes (Fig. 5). Reinforcing this area
may effect energy management.
NOTE: If a reinforcement is required, it should com-
pletely cover the repaired area. The reinforcement
should also overlap the top and bottom of the
frame by more than 50% of its width. Weld as indi-
cated (Fig. 4).
FRAME FASTENERS
Bolts and nuts can be used to repair frames or to
install a reinforcement section on the frame.
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.
SPECIFICATIONS
FRAME DIMENSIONS
Frame dimensions are listed in metric scale. All
dimensions are from center to center of Principle
Locating 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 were applicable.
INDEX
DESCRIPTION
FIGURE
FRAME SIDE VIEW
6
FRAME TOP VIEW
7
FRAME SIDE VIEW LWB
8
FRAME TOP VIEW LWB
9
Fig. 4 FRAME REINFORCEMENT
1 - FRAME CENTER LINE
2 - FRAME
3 - FRAME REPAIR REINFORCEMENT
Fig. 5 ENERGY MANAGEMENT HOLES
1 - ENERGY MANAGEMENT HOLES
13 - 4
FRAME & BUMPERS
TJ
FRAME (Continued)
Fig.
6
FRAME
SIDE
VIEW
TJ
FRAME & BUMPERS
13 - 5
FRAME (Continued)
Fig. 7 FRAME TOP VIEW
13 - 6
FRAME & BUMPERS
TJ
FRAME (Continued)
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