C. Replace Front Suspension Coil Spring Tower(s)
NOTE:Only those trucks that have cracked spring tower(s), as determined by the inspection in Section "B", require replacement. Very few trucks are expected to require coil spring tower replacement.
IMPORTANT:
All welding must be performed by a qualified welder.
^ When replacing the left coil spring tower, perform the following steps to gain access for welding:
a. Remove the left side battery from the vehicle.
b. On diesel equipped trucks, remove the intercooler outlet duct from the truck (Figure 7).
c. On V-10 equipped trucks, remove the air cleaner assembly fresh air tube.
d. With the steering wheel locked in place, disconnect the steering coupler at the steering column (Figure 8).
CAUTION:
Do not turn the steering gear input shaft or steering wheel while the steering coupler is disconnected. This may cause airbag clockspring damage.
^ On diesel equipped trucks, when replacing the right coil spring tower remove the right side battery from the vehicle.
1. Before removing the cracked coil spring tower, scribe horizontal and vertical lines at the bottom corners of the coil spring tower (Figure 9).
2. Remove the cracked coil spring tower by grinding out the original welds using a cut-off wheel.
CAUTION:
Avoid removing frame rail material or scribe lines while grinding.
3. After removing the cracked coil spring tower, repair any damaged metal on the frame rail. Weld all cracks or holes as required.
4. Prepare the welding surfaces by removing all wax, dirt, oil, and paint that may be present.
5. Clamp the new coil spring tower onto the frame rail. Be sure that the new tower lines up with the scribe marks made in Step 1 (Figure 10).
6. Check the weld joints for any gaps that exceed 1/16 inch. If there are any gaps, make the necessary adjustments to ensure gaps do not exceed 1/16 inch.
NOTE:
Refer to the Welding Procedure Specifications Chart for all welding information.
7. Tack weld the coil spring tower into position. Recheck the alignment of the shock tower. Adjust the position of the coil
8. Weld the new coil spring tower into position applying the welds as shown in Figure 11.
NOTE:
Refer to the Welding Procedure Specification Chart (flat, overhead, vertical up or down) to determine the correct direction that welding must be performed (vertical/flat, up or down).
9. Continue with Section "D - Install Front Suspension Coil Spring Tower Reinforcement Brackets."