Operation CHARM: Car repair manuals for everyone.
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

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Service Procedure

Due to the extreme detail of locating the possible missing welds, ALL VEHICLE FRAME WELD INSPECTIONS ARE TO BE PERFORMED BY A REPRESENTATIVE FROM ALCOA, THE FRAME SUPPLIER. Dealers must only provide a service bay with an appropriate hoist for use during the inspection. Be sure to follow the specific service manual procedures for hoisting a Prowler to avoid body damage. The frame inspection will take less than one hour.

If the vehicle requires frame welding, the vehicle must be scheduled for repair with one of the ALCOA frame welding specialists. Dealers must disassemble the appropriate area(s) of the vehicle as necessary, to allow access to the area of the frame that requires welding. All disassembly should be completed prior to the scheduled arrival of the welding specialist. DUE TO THE SPECIALIZED NATURE OF WELDING ALUMINUM, ALL FRAME WELDING MUST BE PERFORMED BY AN ALCOA WELDING SPECIALIST. CONTACT YOUR ZONE OFFICE FOR DISASSEMBLY AND REASSEMBLY PROCEDURES for the affected area(s) requiring welding. Very few vehicles are expected to require frame welding.