FRAME
WARNING
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
• BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
• DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
• WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
• STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
• DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: Do not anchor or support the vehicle on
suspension components during frame straightening
operations. Damage to suspension can result.
• Do not reuse damaged fasteners, quality of
repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure.
• Do not drill any holes in the frame that are not
specifically outlined in this or other,
DaimlerChrysler procedure as frame rail failure can
result.
• When using heat to straighten frame compo-
nents do not exceed 566°C (1050°F), metal fatigue
can result.
• Do not use any flame or plasma cutting equip-
ment to cut the frame in this procedure. This is due
to the inaccurate nature of the cut-line and the fact
that the high temperatures achieved during flame or
plasma cutting will change the metal characteristics
and may weaken the frame and/or repair location.
• Shield the surrounding areas and components
from exposure to the welding spatter and heat.
• Do not anchor vehicle frame rails to pulling
device at locations that are not reinforced. Damage
to the frame rails can result.
• Do not anchor or support vehicle on powertrain
components during frame straightening operations.
Damage to powertrain can result.
• Protect wire harness and plastic components
from excessive heat or sparks during frame repair
operations.
• Protect electrical components from being con-
taminated by metal fragments during grinding or
cutting operations.
• Do not put inserts in collapse areas. Strength-
ening the parts will change the way collision dam-
age is absorbed, possibly endangering the
passengers.
CAUTION: Do not section in the following areas:
• Suspension mounting locations
• Structural part mounting locations
• Dimensional reference holes
• Compound shapes/reinforcements
• Reinforcements (except as noted)
• Compound structures
• Collapse/crush zones
• Engine or drivetrain mounting locations
STANDARD PROCEDURE
FRAME DAMAGE REPAIR
For required warnings and cautions, (Refer to 13 -
FRAME & BUMPERS/FRAME - WARNING).
To achieve proper vehicle ride height after a sus-
pension component has been loosened, the vehicle
must be at design weight and resting on the tires
before the suspension can be tightened. (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - DESIGN
HEIGHT MEASUREMENT - STANDARD PROCE-
DURE)
This frame can be quarter sectioned if the frame
rails cannot be straightened during collision repair.
Only a repair person experienced in structural weld-
ing using a TIG or MIG welder should perform frame
sectioning procedures. (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - WELD-
ING) If a frame must be sectioned or straightened,
upper and lower control arm, shock absorber, steer-
ing gear and rear toe link mounting points must be
in the design location. The upper shock mounting
hole must be properly positioned over the lower con-
trol arm mounting locations to achieve proper ride
height. The steering gear mounts must be properly
positioned to achieve proper front wheel toe pattern.
The rear toe links must be properly positioned to
achieve proper rear wheel toe pattern.
For weld point locations (Refer to 23 - BODY/
BODY STRUCTURE/WELD LOCATIONS - SPECI-
FICATIONS)
ZB FRAME & BUMPERS 13 - 9
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