Dodge Ram Truck 1500-2500-3500. Manual — part 1442

21. Slide the service sleeve (3) into the replacement

frame tip (1) and align to the 2 mm (0.08 in.) off
center line made previously during the sleeve
assembly and tack the ring fillet welds to hold
them in place.

22. On 4X4 models, install the sway bar tapping plate

(5) and secure with tack welds.

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FRAME & BUMPERS

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23. Apply ring-fillet welds (3) into the ring-fillet weld

holes on the replacement frame tip. (Refer to 13 -
FRAME

&

BUMPERS/FRAME

-

SPECIFICA-

TIONS - WELDING)

24. Start the ring-fillet welds at location (1) and follow

around the circumference of the ring-fillet weld
hole and end weld overlapping start point (2).

25. Install the upper FESM insulator onto the replace-

ment tip and position the service sleeve/replace-
ment tip into the existing frame rail.

26. Loosely install the lower FESM insulator and cab

mounting bolt.

27. Using the appropriate measuring equipment, ver-

ify the front end sheet metal bracket’s location in
all three (X,Y, and Z) planes of space, and adjust
if required.

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FRAME & BUMPERS

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CAUTION: Shield the surrounding area and com-
ponents from exposure to the welding spatter and
heat.

28. When correctly fitted and a weld root gap of 4 mm

minimum to 6 mm maximum (0.16 in - 0.24 in) is
established, tack the ring fillet welds to hold the
tip in position, then complete the ring fillet welds
(3).

NOTE: Ring-fillet welds may be filled in with weld
material if an improved cosmetic appearance is
desired.

29. Confirm alignment of the replacement frame rail

tip (4).

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FRAME & BUMPERS

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30. Final welding should be performed in a skip

(stitch) type method to minimize the heat buildup
and frame distortion, utilizing the Weld Process
Specifications at the end of this section. The pre-
ferred method is GMAW (MIG). (Refer to 13 -
FRAME

&

BUMPERS/FRAME

-

SPECIFICA-

TIONS - WELDING)

a. Apply root pass welds (4) to the root joint one

quadrant at a time, switching to the opposite
side of the frame for each quadrant.

b. Clean the welds of any flux and other impuri-

ties before proceeding with the cover pass
welds (5).

c. Apply the cover pass welds (5) in the same

manner as described above.

31. Confirm alignment of the replacement frame rail

tip (4).

NOTE: Any burned surface coatings will need to
be removed prior to application of corrosion pre-
ventative coatings.

32. Dress the welded area and apply corrosion resis-

tant 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 reinforcing sleeve.

c. Apply a durable top coat to the outside of the

repair area.

33. Tighten the front cab mounting bolt to the FESM

bracket to 81 N·m (60 ft. lbs.).

34. Install the stabilizer bar. (Refer to 2 - SUSPEN-

SION/FRONT/STABILIZER

BAR

-

INSTALLA-

TION)

35. Install the front bumper. (Refer to 13 - FRAME &

BUMPERS/BUMPERS/FRONT

BUMPER

-

INSTALLATION)

36. Install the wire harness and ground strap if previ-

ously removed and install the bolt.

a. If necessary, re-drill and tap the ground strap

mounting hole

37. Install the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE SPLASH

SHIELD - INSTALLATION)

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FRAME & BUMPERS

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