CAUTION: Do not use any flame or plasma cutting equipment to cut the frame inthis procedure. The inac-
curate and high temperatures achieved during flame or plasma cutting willchange the metal characteristics
and may weaken the frame and/or repair location.
12. Carefully remove the H-section welds using a grinder or equivalent tool.
13. Remove the H-section and clean any remaining welds from the frame.
14. Trial fit the replacement part.
15. Remove all e-coat from within 25 mm (1.0 in.) of the weld area.
16. Using the appropriate measuring equipment, position the replacementpart and verify correct positioning in all
three (X,Y, and Z) planes of space. (Refer to 13 - FRAME & BUMPERS/FRAME - SPECIFICATIONS - FRAME
DIMENSIONS)
CAUTION: Shield the surrounding area and components from exposure to the welding spatter and heat.
17. Weld the replacement H-section into position. The welding should be performedinaskip(stitch)typemethod
to minimize the heat buildup followingI-CAR or the American Welding Society welding procedures and utilizing
the process specifications at the end of this section. (Refer to 13 - FRAME &BUMPERS/FRAME - SPECIFI-
CATIONS - WELDING)
18. Dress the welded area and apply corrosion resistant coatings inside and out.
a. Inside the rail, inject a creeping wax based rust inhibitor compound through the existing holes in the frame
ensuring 100% coverage including the mating face between the frame and replacement H-section.
b. Apply a durable top coat to the outside of the repair area.
19. Position the wiring harness back.
CAUTION: Inspect the tire winch assembly (1) 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 hous-
inginanyway.
20. Install the spare tire winch (1) and install the bolts
(2).
21. Tightentheboltsto41Nꞏm(30ft.lbs.).
22. Install the spare tire winch tube (3) and install the
clip (2).
23. Install the spare tire.
CAUTION: Check operation of the spare tire winch
by manipulating it up and down. If the winch binds
or jambs, replace the winch assembly.
CAUTION: 3500 Dual rear tires have a new tire
rotation pattern. This is to accommodate the out-
lined white letter (OWL) tires. When replacing a
flat, the spare tire may have to be remounted on
the rim or installed at a different location to main-
tain the correct placement of the outlined white
letter (OWL) tires.
The recommended method of tire rotation for dual rear
wheel is. Other methods can be used, but may not
provide the same tire longevity benefits.
SPECIFICATIONS
TORQUE
DESCRIPTION Nꞏm Ft. Lbs. In. Lbs.
1500 Series
Lug Nut 9/16 X 18 with
60° Cone
LD176 130 —
2500 Series
Lug Nut 9/16 X 18 with
60° Cone
HD SRW190 140 —
3500 Series
Lug Nut 9/16 X 18 with
Flat Washer
HD DRW197 145 —
