Dodge Ram Truck 1500-2500-3500. Manual — part 1444

11. Remove the upper radiator crossmember (4). (Refer to 23 - BODY/EXTERIOR/UPPER RADIATOR CROSS-

MEMBER - REMOVAL).

12. Remove the headlamp unit (5) (Refer to 8 -

ELECTRICAL/LAMPS/LIGHTING

-

EXTERIOR/

HEADLAMP UNIT - REMOVAL).

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13. Remove the front cab mount to the Front End Sheet Metal bracket (FESM) bolt (2).

14. Remove the bolts (5) attaching the lower radiator crossmember (6) to the hydroform fender rail (1).

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CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in this procedure. The inac-
curate and high temperatures achieved during flame or plasma cutting will change the metal characteristics
and may weaken the frame and/or repair location.

15. Using a reciprocating saw or equivalent, cut the fender rail and shotgun at a straight and square section of the

hydroform and remove.

16. Smooth and square the cut edges.

17. Using the damaged structure as a reference cut the service part at the same location as the first cut. Smooth

and square the cut edges.

NOTE: The repair structure should butt up to the remaining structure and provide the same overall vehicle
geometry.

18. Fabricate 51 mm (2.0 in.) long repair inserts using scrap from the old structure or the replacement part. It will

be necessary to split the inserts on each of their four sides to fit into the hydroform.

19. Remove any paint or e-coat from the inserts and also to the interior and exterior of the hydroforms.

20. Cut plug weld holes as described below.

•

On the upper rail, cut one 13 mm (0.5 in.) hole on each side of the rail, 25 mm (1.0 in.) from the butt joint of
the tubes.

•

On the lower rail, cut one 13 mm (0.5 in.) hole on the top and bottom sides of the rail 25 mm (1.0 in.) from the
butt joint of the tube.

•

On the lower rail, cut two 13 mm (0.5 in.) holes on the inner and outer sides of the rail 25 mm (1.0 in.) from
the butt joint of the tube.

CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.

21. Install the insert 1” into the replacement part and tack into place with a weld. (Refer to 13 - FRAME &

BUMPERS/FRAME - SPECIFICATIONS - WELDING)

22. Insert the service part into place and using the appropriate measuring equipment, verify the front end sheet

metal bracket’s location in all three (X,Y, and Z) planes of space.

23. Complete all 360° plug welds.

NOTE: Before the final welding, use three dimensional measuring equipment to ensure the part is in the
correct location. Verify that tap plate extrusion at the bottom of the vertical post lines up with the isolator
and hole in the frame perch mount. Also ensure the lower radiator closure tube is bolted into the forward
shotgun ends.

24. Complete welding by making a 360° butt weld around the fender rails.

25. Metal finish the exposed welds on the hydroforms.

26. Dress the welded area and apply corrosion resistant coatings inside and out.

a. Inside the rail, inject a creeping wax based rust inhibitor compound to the inside of the hydroforms ensuring

100% coverage including the mating face between the fender rail sections and insert such that corrosion
protection is restored in the internal cavity.

b. Apply a durable top coat to the outside of the repair area.

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27. Install the front cab mount bolt (2) if previously removed and tighten to 81 N·m (60 ft. lbs.).

28. Install the lower radiator crossmember (6) bolts (5) and tighten to 28 N·m (21 ft. lbs.).

29. Install the headlamp unit (Refer to 8 - ELECTRI-

CAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP
UNIT - INSTALLATION).

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