(1) The frame should be straightened and squared
before removing the front frame assembly (Refer to
13 - FRAME & BUMPERS/FRAME - SPECIFICA-
TIONS - FRAME DIMENSIONS).
(2) Use a die grinder or reciprocating saw.
(3) Determine the area where the new section is to
be installed. This depends on the splice method being
used (overlap or insert).
Installation
(1) Mount and temporarily tack weld the new sec-
tion into place (Refer to 13 - FRAME & BUMPERS/
FRAME - SPECIFICATIONS - WELDING).
(2) Measure for square and check all alignment
dimensions (Refer to 13 - FRAME & BUMPERS/
FRAME - SPECIFICATIONS).
(3) Complete welding (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - WELD-
ING).
(4) Dress the welded area and apply corrosion
resistant 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 rein-
forcing sleeve.
(c) Apply a durable top coat to the outside of the
repair area.
FRAME SIDE SILL ASSEMBLY
WARNINGS AND CAUTIONS
For required warnings and cautions, (Refer to 13 -
FRAME & BUMPERS/FRAME - WARNING).
CAUTION: When removing damaged side sills, care
should be taken not to damage the adjacent panels.
CAUTION: Remove all flammable materials before
grinding or welding.
NOTE: Door surround panels must be removed to
replace side sill panels.
NOTE: The side sills come with all related bracing,
weld nuts, and jack locator.
Removal
(1) Remove the screws at the lower toe box to side
sill.
(2) Cut all welds using a die grinder or equivalent.
(3) Clean all sealer from the component surfaces.
Installation
(1) Fit the new side sill assembly into place, and
check for fit and alignment.
(2) Apply sealer to toe box attaching area.
(3) Install bolts at toe box attaching area.
(4) Tack weld side sill into place.
(5) Re-check the alignment.
(6) Complete MIG stitch and butt welds.
(7) Apply sealer to floor pan/side sill mating area.
(8) Treat all repair areas with corrosion protection.
REAR UPPER FRAME RAIL ASSEMBLY
WARNINGS AND CAUTIONS
For required warnings and cautions, (Refer to 13 -
FRAME & BUMPERS/FRAME - WARNING).
NOTE: When replacing the upper rear rail, if only a
section of it is used, DO NOT put inserts into col-
lapse areas. Strengthening the parts will change the
way collision damage is absorbed, possibly endan-
gering the passengers. Do not section in the follow-
ing 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
NOTE: The upper rear rail assemblies come com-
plete with all mounts, hardware, and bracing
required to complete the repair.
• The trunk pan assembly must be removed
when replacing the entire upper rail assembly.
• Remember to remove all flammable materials
before beginning this repair.
Removal
(1) The frame should be straightened and squared
before removing the damaged upper frame rail
assembly.
(2) Cut all MIG butt welds securing upper rear
frame rail to lower main frame rails, diagonal braces
and cross braces.
(3) Clean and prep all remaining frame tubing for
new rail installation.
Installation
(1) If replacing entire rail, position, measure, and
align new rail and tack weld into place (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECIFICATIONS -
WELDING).
ZB FRAME & BUMPERS 13 - 11
FRAME (Continued)
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