Frame Maintenance - Welding Precautions

WELDING PRECAUTIONS

1. CAUTION: When welding is performed anywhere on the vehicle, precautionary measures should be taken to prevent damage to electrical system wiring or components. Prior to welding, any parts which could be damaged by excessive temperatures should be removed or adequately shielded. Also prior to welding, disconnect both batteries, then the ABS module, then the PCM. The welding ground clamp should be positioned as close to the affected welding area as possible. Computer processors should be removed if welding is to be done within their close proximity. Welding cables should never be allowed to lay on, near, or across any electrical wiring or electronic component during welding. After welding, when parts are cool, carefully inspect wiring and electrical components for shorts or other damage which could draw excessive currents and possibly cause an electrical system short when the battery is reconnected.

When welding low carbon steel side rails (35,000 psi yield strength), emphasis should be placed upon weld application techniques to avoid stress risers that may adversely affect frame operating stresses. When welding within 4 inches of any crossmember rivet, remove the rivets and replace with grade 8 bolt/nuts.

NOTE:
- Do not weld on any reinforcement. Use compression type fasteners when attaching any component to the frame in the reinforcement area.
- On Motor home, welding to the frame flange is not recommended; welding to the vertical side web is preferred.

If welding must be done on a frame (5005), make sure the following requirements are met:
- If the frame is attached to the vehicle, the battery ground cable (14301) must be disconnected before using any electrical welding equipment.
- Do not use gas welding equipment; mig welding is the only approved method.
- Replace spot-welded components by spot welding where possible.
- If spot welding is not possible, use puddle welding.