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Fig. 10 160.5 IN WHEELBASE - 3500 - 4 WHEEL DRIVE
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TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION Nꞏm Ft. Lbs.
Cab mount bolts 81 60
Cargo box bolts 108 80
Front crossmember bolts - 2WD (light duty only) 61 45
Front crossmember bolts - 2WD (heavy duty only) 75 55
Front crossmember bolts - 4WD (light duty only) 102 75
Front skid plate bolts 34 25
Lower bumper support bracket bolt 54 40
Radiator crossmember bolts - lower 28 21
Radiator crossmember bolts - upper 28 21
Rear crossmember (light duty only) 102 75
Rear crossmember (heavy duty only) 115 85
Rear spring shackle bolts 163 120
Sparetirewinchbolts 41 30
Trailer hitch reinforcement bracket bolt 170 125
Transfercase skid plate bolts 34 25
Transercase skid plate crossmember bolts 34 25
Transmission mount to crossmember nuts 54 40
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FRONT CROSSMEMBER
REMOVAL
1. Raise and support the vehicle (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE).
2. Remove the front skid plate (2 - if equipped) (Refer
to 13 - FRAME & BUMPERS/FRAME/FRONT SKID
PLATE - REMOVAL).
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3. On the 2WD models, remove the bolts (2) and
remove the crossmember (1).
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 dur-
ing flame or plasma cutting will change the metal
characteristics and may weaken the frame and/or
repair location.
4. On SRT-10 vehicles, remove the welds using a
grinder or equivalent.
5. On the 4WD models, remove the bolts (1) and
remove the crossmember (2).
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INSTALLATION
1. Install the crossmember (1).
2. Install the bolts (2);
On light duty 2WD vehicles, tighten the bolts to
61 Nꞏm (45 ft. lbs.).
On heavy duty 2WD vehicles, tighten the bolts to
75 Nꞏm (55 ft. lbs.).
3. On 4WD models, install the crossmember (2).
4. Install the bolts (1) and tighten to 102 Nꞏm (75 ft.
lbs.).
5. Remove all OEM e-coat within 51 mm (2.0 in.) of
the weld on both the crossmember and the frame.
CAUTION: Shield the surrounding area and com-
ponents from exposure to the welding spatter and
heat.
6. Using the Weld Process Specifications table (Refer
to 13 - FRAME & BUMPERS/FRAME - SPECIFI-
CATIONS - WELDING), apply new welds to the
SRT-10 crossmember.
NOTE: Any burned surface coatings will need to
be removed prior to application of corrosion pre-
ventative coatings.
7. Dress the welded area and apply corrosion resis-
tant coatings.
a. Apply etch-primer to the repair area.
b. Apply a durable top coat to the outside of the repair area.
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8. Install the front skid plate, if equipped (2) (Refer to
13 - FRAME & BUMPERS/FRAME/FRONT SKID
PLATE - INSTALLATION)
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FRONT SKID PLATE
REMOVAL
1. Raise and support the vehicle (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE).
2. Remove the bolts (3).
3. Slide skid plate (2) back off of the crossmember (1)
and remove.
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INSTALLATION
1. Snap the rear tabs over the front crossmember (1)
and install the skid plate (2).
2. Install the bolts (3) and tighten to 34 Nꞏm (25 ft.
lbs.).