Dodge Dakota (R1). Manual — part 553
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 5 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.
Fig. 3 4X2 Frame
1 - CENTER BEARING CROSSMEMBER
2 - FUEL TANK CROSSMEMBER
3 - TRAILER HITCH
4 - FRAME
13 - 4
FRAME & BUMPERS
AN
FRAME (Continued)
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 frame side rail top and bottom
flanges, metal fatigue can result causing frame fail-
ure. 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.
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. 8) over the repaired area.
Fig. 4 4X4 Frame
1 - FUEL TANK CROSSMEMBER
2 - TRAILER HITCH
3 - FRAME
AN
FRAME & BUMPERS
13 - 5
FRAME (Continued)
NOTE: If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches nar-
rower than the side rail flanges. Weld only in the
areas indicated (Fig. 8).
FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
Bolts can be used in place of rivets. When replacing
rivets with bolts, install the next larger size diameter
bolt to assure proper fit. If necessary, ream the hole
out just enough to sufficiently receive the bolt.
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.
Fig. 5 Cab Mounts
1 - FLOOR PAN
2 - REAR CAB ISOLATOR
3 - UNDER CAB ISOLATOR
4 - UNDER CAB ISOLATOR
5 - FRAME
6 - FRONT CAB ISOLATOR
Fig. 6 Radiator Closure Panel
1 - RADIATOR CLOSURE PANEL
2 - FRAME
3 - ISOLATOR
4 - ISOLATOR
13 - 6
FRAME & BUMPERS
AN
FRAME (Continued)
Fig. 7 Cargo Box
1 - CARGO BOX
2 - FRAME RAIL
Fig. 8 Frame Reinforcement
1 - .250 IN FROM EDGE
2 - TOP FLANGE
3 - BOTTOM FLANGE
4 - FRAME RAIL
5 - FRAME REPAIR REINFORCEMENT
AN
FRAME & BUMPERS
13 - 7
FRAME (Continued)
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