REAR BUMPER

REMOVAL

(1) Raise and support the vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
(2) Remove the license plate.
(3) Remove the bolts behind the plate.
(4) Disconnect the license plate light electrical connectors.
(5) Disconnect the trailer light connector electrical connection, if equipped.
(6) Remove the two bolts along the front upper edge of the bumper near the frame tips.
(7) Support the bumper with a suitable lifting device.
(8) Remove the bolts attaching the bumper support brackets to the trailer hitch. (Fig. 5)

TRAILER HITCH

1 - HITCH
2 - HITCH BOLTS (4)
3 - BUMPER BRACKET BOLTS (4)
4 - BUMPER SUPPORT BRACKETS

INSTALLATION

(1) Align the holes in the bumpers to the trailer hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts, loosely.
(3) Install the front upper edge to the trailer hitch bolts and tighten to 54 N·m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch bolts and tighten to 54 N·m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54 N·m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54 N·m (40 ft. lbs.).
(7) Connect the trailer light connector electrical connection, if equipped.
(8) Connect the license plate light electrical connectors.
(9) Install the license plate.

FRAME

STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT
FRAME RAIL TIP REPLACEMENT

(1) Disconnect and isolate the battery negative cable.
(2) Remove the front wheelhouse splash shield. Refer to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE SPLASH SHIELD - REMOVAL)
(3) Remove the bolts and position aside the wire harness and grounds, if required.
(4) Remove the front bumper. (Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT BUMPER - REMOVAL)
(5) Loosen and lower the stabilizer bar mount and bar. (Refer to 2 - SUSPENSION/FRONT/STABILIZER BAR - REMOVAL)
(6) Remove the front cab mount bolt to the Front End Sheet Metal (FESM) bracket. (Fig. 6)

REPLACEMENT FRAME TIP

1 - FRONT END SHEET METAL (FESM) BRACKET
2 - CAB INSULATOR
3 - RING-FILLET WELD/HOLE
4 - PRINCIPLE LOCATING POINT (PLP)
5 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.)
6 - FRONT CAB MOUNT BOLT
7 - REPLACEMENT FRAME TIP

(7) Make a vertical mark on the inside and outside face of the frame rail 112 mm (4.5 in.) from the forward edge of the PLP hole in the sides of the rail. (Fig. 8)
(8) Using a straightedge, connect the two lines on the top and bottom of the rail.
(9) Using the service tip as a guide, re-check your cut lines to ensure the service tip will fit when the cut is made.

CAUTION: Do not use any flame or plasma cutting equipment 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.

(10) Using a reciprocating saw or equivalent, carefully cut and remove the damaged frame rail tip. (Fig. 7)

FRAME CUT LOCATION

1 - REPAIR ROOT OPENING
2 - SERVICE SLEEVE
3 - PRINCIPLE LOCATING POINT (PLP)
4 - SUSPENSION BRACKETS
5 - FRAME
6 - FRAME CUTOFF LOCATION - 112 mm (4.5 in.)
7 - FRAME SERVICE TIP

(11) Assemble the service sleeve. Refer to SERVICE SLEEVE ASSEMBLY at the end of this procedure.

NOTE: Any burned surface coatings will need to be removed from the sleeve prior to installation and application of corrosion preventative coatings.

(12) Smooth and square the cut edges of the original frame. (Fig. 7)
(13) Dress the cut edge of the existing frame in preparation for the new rail tip. (a) Drill four 13 mm (0.5 in.) diameter holes in the new tip and four more in the existing frame to accommodate ring-fillet welds. Center these holes 19 mm (0.75 in.) from the cut face of the rail and 38 mm (1.5 in.) from the top and bottom of the rail. (Fig. 8) (b) Bevel the edges of the new tip, existing frame, and ring-fillet holes 25° - 30°. Scribing a line 2 mm from the cut edge and then grinding back to the mark will simplify the bevel creation process and accuracy. (Fig. 9) (c) Remove any burrs at the holes and beveled edges.

REPAIR SLEEVE INSTALLATION (TYPICAL)

1 - REPLACEMENT FRAME TIP
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - CENTER LINE
5 - LOCATOR LINES (2)
6 - HORIZONTAL WELD HOLE LOCATION - 38 mm (1.5 in.)(BOTH FRAME SECTIONS)
7 - LOCATOR LINE DIMENSION - 2 mm (0.08 in.)
8 - VERTICAL WELD HOLE LOCATION - 19 mm (0.75 in.)(BOTH FRAME SECTIONS)
9 - RING FILLET WELD HOLES

WELD DIMENSIONS

1 - FRAME REPLACEMENT TIP
2 - FRAME RAIL
3 - FRAME DRESS ANGLE 25°-30°
4 - ROOT PASS
5 - COVER PASS
6 - SERVICE SLEEVE
7 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.)
8 - SERVICE SLEEVE

(14) Dry fit the new rail to ensure alignment and fit and make any adjustments as necessary.
(15) Remove all internal and external OEM e-coat within 51 mm (2.0 in.) of the weld joint on the replacement tip and the existing frame rail.

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

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

(16) On 4X4 models use the service sleeve as a template to drill a hole in the frame tip to accommodate the sway bar mounting bolt. (Fig. 12)
(17) Slide the service sleeve into the replacement frame tip 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. (Fig. 10) (Fig. 11) (Fig. 12) (Fig. 13)
(18) On 4X4 models, install the sway bar tapping plate and secure with tack welds. (Fig. 12) (Fig. 13)
(19) Apply ring-fillet welds into the ring-fillet weld holes on the replacement frame tip, using the Weld Process Specifications table. (Fig. 14)
(20) Install the upper FESM insulator onto the replacement tip and position the service sleeve/replacement tip into the existing frame rail.
(21) Loosely install the lower FESM insulator and cab mounting bolt.
(22) Using the appropriate measuring equipment, verify the front end sheet metal bracket’s location in all three (X,Y, and Z) planes of space, and adjust if required. (Fig. 15)

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

(23) 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.

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

(24) Confirm alignment of the replacement frame rail tip. (Fig. 15)
(25) 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 preferred method is GMAW (MIG). (a) Apply root pass welds to the root joint one quadrant at a time, switching to the opposite side of the frame for each quadrant. (Fig. 9) (b) Clean the welds of any flux and other impurities before proceeding with the cover pass welds. (c) Apply the cover pass welds in the same manner as described above.
(26) Confirm alignment of the replacement frame rail tip. (Fig. 15)

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

(27) 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 reinforcing sleeve.
(28) Tighten the front cab mounting bolt to the FESM bracket to 81 N·m (60 ft. lbs.).
(29) Install the stabilizer bar. (Refer to 2 - SUSPENSION/ FRONT/STABILIZER BAR - INSTALLATION)
(30) Install the front bumper. (Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT BUMPER - INSTALLATION)
(31) Install the wire harness and ground strap if previously removed and install the bolt. (a) If necessary, re-drill and tap the ground strap mounting hole
(32) Install the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE SPLASH SHIELD - INSTALLATION)

CAUTION: All welds should conform to DaimlerChrysler vehicle engineering process standard “PS 9472”.

19 HYDROFORM FENDER RAILS

1 - HYDROFORM FENDER RAIL
2 - FRONT END SHEET METAL BRACKET
3 - UPPER RADIATOR CROSSMEMBER BOLTS (4)
4 - UPPER RADIATOR CROSSMEMBER
5 - LOWER RADIATOR CROSSMEMBER BOLTS (8)
6 - LOWER RADIATOR CROSSMEMBER

ENGINE COMPARTMENT/FRONT STRUCTURE

(26) Install the front cab mount bolt if previously removed and tighten to 81 N·m (60 ft. lbs.).
(27) Install the lower radiator crossmember bolts and tighten to 28 N·m (21 ft. lbs.).
(28) Install the headlamp unit. (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT - INSTALLATION)
(29) Install the upper radiator crossmember. (Refer to 23 - BODY/EXTERIOR/UPPER RADIATOR CROSSMEMBER - INSTALLATION)
(30) Install the wire harness and ground if previously removed and install the bolts.
(31) Install the integrated power module, if previously removed. (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - INSTALLATION)
(32) Install the air cleaner bracket and air cleaner, if previously removed. (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - INSTALLATION)
(33) Install the radiator assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR - INSTALLATION)
(34) Install the A/C lines, if previously removed. Refer to the Heating and Air Conditioning section of the manual for the recommended procedures.
(35) Install the A/C condenser, if previously removed. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/A/C CONDENSER - INSTALLATION)
(36) Install the fender. (Refer to 23 - BODY/EXTERIOR/ FRONT FENDER - INSTALLATION)
(37) Install the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE SPLASH SHIELD - INSTALLATION)
(38) Reconnect the battery ground.