Standard Procedure - Front Frame Rail Tip Replacement: Notes
CAUTION:
This procedure is designed to replace the front frame rail tips that have been damaged in the crush initiator zones. Prior to any cutting, the vehicle must be mounted on the appropriate frame repair equipment (frame rack), checked with three dimensional measuring equipment, and the necessary pull corrections made without the use of heat. Refer to Frame, Specifications .
- If damage remains in the frame beyond the area covered by this service part after the pull, the frame must be replaced in its entirety.
- If damage to the front body structure is evident, repair the Front End Sheet Metal (FESM) fender rails as necessary.
CAUTION:
Inspect the tire winch assembly for damage. If any one or more of the following are evident, replace the winch assembly.
- Indications of cracked or bulging plastic.
- Housing flanges are bent or cracked.
- If winch was loose before repair.
- If the rivet heads are separated from the housing in any way.
- Before proceeding with this repair procedure review the required service warnings and precautions. Refer to Frame, Warning .
- Disconnect and isolate the battery negative cable.
1 - FESM STRUCTURE 2 - RIGHT SIDE FRAME RAIL 3 - FESM STRUCTURE 4 - LEFT SIDE FRAME RAIL 5 - FRONT RAIL CAP PANEL (TYPICAL BOTH SIDES) 6 - LOWER RADIATOR CROSSMEMBER - With vehicle mounted to appropriate pulling and 3-dimensional measuring equipment, complete the following procedure paying particular attention to body dimensions while fitting and welding panels.
- Remove bumper components, cooling module, headlamp, and all other components for clear access to repair area.
- Remove front rail cap panel (5) on damaged rail.
- Remove welds holding lower radiator crossmember (6) to damaged rail (if crossmember is damaged, remove completely).
- Remove welds holding FESM structure (1 and 3) to rail (if damaged, remove complete assembly).