D. Install Frame Gussets

1. Using a cut off wheel or grinder, grind off the welds that hold the left and right side frame rail gussets to the frame rails (Figure 10).

CAUTION:
Do not use plasma arc cutting equipment or a cutting torch to remove the frame rail gussets.

2. If required, use a chisel to remove the old gussets after welds are ground off.

3. After the old gussets have been removed, grind off any remaining weld from the frame rail areas.

4. Thoroughly clean and degrease the frame rail. Then apply zinc rich primer to all bare metal.

5. After the zinc rich primer is dry, apply black spray paint to cover the zinc rich primer applied in Step 4.





6. Position and clamp the new left side gusset into place (Figure 11).

NOTE:
Right and left side gussets are not interchangeable. Make sure that the correct gusset is being installed.

7. Using the new gusset as a template, drill eleven 1/4 inch (6.35 mm) holes into the frame rail.

8. Brush zinc primer into holes drilled in Step 7 to prevent corrosion.

9. Using power rivet gun P/N W-AK175ACH) or equivalent, rivet the new gusset into place using the provided structural rivets.

10. Remove clamps from the gusset.

11. Apply a coat of black spray paint over the rivet heads.

12. Repeat steps 6 through 11 to install the new gusset on the right side frame rail gusset.

13. ^ If the vehicle had the steering gear crossmember replaced, continue with Section "E - Wheel Alignment."

^ If the vehicle did not have the steering gear crossmember replaced, wheel alignment is not required. No further action is necessary. Return the vehicle to the customer.