service DODGE RAM 1500 1998 2.G Workshop Manual

(23) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.
(24) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(25) Install the radiator upper hose and clamps.
(26) Add engine oil.
(27) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(28) Connect the battery cables.
(29) Start engine and inspect for leaks.
GEAR HOUSING COVER
REMOVAL
(1) Disconnect both battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(9) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(10) Remove the cooling fan support/hub from the
front of the engine.
(11) Raise the vehicle on hoist.
(12) Remove power steering pump.
(13) Remove accessory drive belt tensioner.
(14) Remove the crankshaft damper and speed
indicator ring (Refer to 9 - ENGINE/ENGINE
BLOCK/VIBRATION DAMPER - REMOVAL).
(15) Lower the vehicle.
(16) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
INSTALLATION
(1) Install a new front crankshaft oil seal.
(2) Obtain a seal pilot/installation tool from a
crankshaft front seal service kit and install the pilot
into the seal.
(3) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover.
Be sure to surround all through holes.(4) Using the seal pilot to align the cover (Fig.
123), install the cover to the housing and install the
bolts. Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(5) Remove the seal pilot. Install front seal dust
shield.
(6) Raise the vehicle.
(7) Install the speed indicator ring and the crank-
shaft damper (Refer to 9 - ENGINE/ENGINE
BLOCK/VIBRATION DAMPER - INSTALLATION).
(8) Lower vehicle.
(9) Install the fan support/hub assy, and tighten
bolts to 32 N´m (24 ft. lbs.) torque.
(10) Install power steering pump.
(11) Install accessory drive belt tensioner. Torque
bolt to 43 N´m (32 ft. lbs.) torque.
(12) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Install the cooling fan and shroud together
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(14) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.
(15) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(16) Install the radiator upper hose and clamps.
(17) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(18) Connect the battery cables.
(19) Start engine and inspect for leaks.
Fig. 123 Installing Cover with Seal Pilot
1 - SEAL PILOT
DRENGINE 5.9L DIESEL 9 - 301
GEAR HOUSING (Continued)

SPECIAL TOOLS
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stainless steel catalytic converter body is
designed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces-
sive heat will not be the fault of the converter. If
unburned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct the
cause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emission vehicles incorporate two mini
catalytic converters located after the exhaust mani-
folds and before the inline catalytic converter.
OPERATION
The catalytic converter captures and burns any
unburned fuel mixture exiting the combustion cham-
bers during the exhaust stroke of the engine. This
process aids in reducing emissions output.
REMOVAL
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the bolts from the crossover pipe to the
catalytic converter connection.
(4) Disconnect oxygen sensor wiring.
(5) Loosen the nuts from the clamp that hold the
catalytic converter to the exhaust pipe flange connec-
tion.
NOTE: Do not remove nut from T-Bolt. Only remove
nut far enough, so that the T end can be removed
from the clamp.
(6) Remove the T bolt end of the fastener, from the
clamp.
(7) Spread the clamp, and remove the catalytic
converter from the vehicle.
(8) Discard the clamp.
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
REMOVAL
(1) Raise and support vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts.
(4) Remove the catalytic converter.
INSPECTION
Look at the stainless steel body of the converter,
inspect for bulging or other distortion that could be a
result of overheating. If the converter has a heat
shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tap-
ping the bottom of the catalyst with a rubber mallet
may indicate a damaged core.
INSTALLATION
INSTALLATION
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
TURBOCHARGER TESTER 9022
11 - 6 EXHAUST SYSTEMDR
EXHAUST SYSTEM (Continued)

(9) Remove the turbocharger and gasket from the
exhaust manifold.
(10) If the turbocharger is not to be installed
immediately, cover the opening to prevent material
from entering into the manifold.
(11) If replacing the turbocharger, transfer the tur-
bocharger oil supply fitting to the new assembly.
Tighten fitting to 36 N´m (27 ft. lbs.).
(12) Clean and inspect the sealing surface.
CAUTION: The turbocharger is only serviced as an
assembly. Do not attempt to repair the turbocharger
as turbocharger and/or engine damage can result.
CLEANING
WARNING: To prevent damage or personal injury,
do not use a combustable cleaner to clean the tur-
bocharger.
Clean the turbocharger and exhaust manifold
mounting surfaces with a suitable scraper.
INSPECTION
Visually inspect the turbocharger and exhaust
manifold gasket surfaces. Replace stripped or eroded
mounting studs.
(1) Visually inspect the turbocharger for cracks.
The following cracks are NOT acceptable:
²Cracks in the turbine and compressor housing
that go completely through.
²Cracks in the mounting flange that are longer
than 15 mm (0.6 in.).
²Cracks in the mounting flange that intersect
bolt through-holes.
²Two (2) Cracks in the mounting flange that are
closer than 6.4 mm (0.25 in.) together.
(2) Visually inspect the impeller and compressor
wheel fins for nicks, cracks, or chips. Note: Some
impellers may have a factory placed paint mark
which, after normal operation, appears to be a crack.
Remove this mark with a suitable solvent to verify
that it is not a crack.
(3) Visually inspect the turbocharger compressor
housing for an impeller rubbing condition (Fig. 20).
Replace the turbocharger if the condition exists.
(4) Measure the turbocharger axial end play:
(a) Install a dial indicator as shown in (Fig. 21).
Zero the indicator at one end of travel.
(b) Move the impeller shaft fore and aft and
record the measurement. Allowable end play is
0.026 mm (0.0001 in.) MIN. and 0.127 mm (0.005
in.) MAX. If the recorded measurement falls out-
side these parameters, replace the turbocharger
assembly.(5) Measure the turbocharger bearing radial clear-
ance:
(a) Insert a narrow blade or wire style feeler
gauge between the compressor wheel and the hous-
ing (Fig. 22).
(b) Gently push the compressor wheel toward
the housing and record the clearance.
(c) With the feeler gauge in the same location,
gently push the compressor wheel away from the
housing and again record the clearance.
(d) Subtract the smaller clearance from the
larger clearance. This is the radial bearing clear-
ance.
(e) Allowable radial bearing clearance is 0.33
mm (0.013 in.) MIN. and 0.50 mm (0.020 in.) MAX.
If the recorded measurement falls outside these
specifications, replace the turbocharger assembly.
INSTALLATION
(1) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 43 N´m (32 ft. lbs.) torque.
Fig. 20 Inspect Compressor Housing for Impeller
Rubbing Condition
Fig. 21 Measure Turbocharger Axial End Play
DREXHAUST SYSTEM 11 - 15
TURBOCHARGER (Continued)

CAUTION: Do not apply more than 138 kPa (20 psi)
air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.
(3) Connect a regulated air supply to air fitting on
Tool 9022 Adapter. Set air pressure to a Maximum of
138 kPa (20 psi).
(4) Using soapy water check the rubber sleeves,
charge air cooler and intake manifold for leaks.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
(1) Disconnect the battery negative cables.
(2) Discharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (if A/C
equipped).
(3) Remove the transmission auxiliary cooler
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - REMOVAL).
(4) Remove the boost tubes from the charge air
cooler (Fig. 24).
(5) Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If the engine experiences a turbocharger failure
or any other situation where oil or debris get into the
charge air cooler, the charge air cooler must be
cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.
(4) Shake the cooler and lightly tap on the end
tanks with a rubber mallet to dislodge trapped
debris.
(5) Continue flushing until all debris or oil are
removed.
(6) Rinse the cooler with hot soapy water to
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks,
holes, or damage. Inspect the tubes, fins, and welds
for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge
Air Cooler Tester Kit #3824556. This kit is available
through CumminstService Products. Instructions
are provided with the kit.
INSTALLATION
(1) Position the charge air cooler. Install the bolts
and tighten to 2 N´m (17 in. lbs.) torque.
(2) Install the air intake system tubes to the
charge air cooler. With the clamps in position, tighten
the clamps to 11 N´m (95 in. lbs.) torque.
(3) Install the transmission auxiliary cooler (if
equipped) (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - INSTALLATION).
(4) Install the A/C condenser (if A/C equipped)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - INSTALLATION).
Recharge A/C system (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(5) Connect the battery negative cables.
(6) Start engine and check for boost system leaks.
Fig. 24 Air Intake System Tubes
1 - BOLT
2 - CHARGE AIR COOLER
3 - CLAMP
4 - BOOST TUBE
DREXHAUST SYSTEM 11 - 17
CHARGE AIR COOLER AND PLUMBING (Continued)

INSTALLATION
(1) Align the holes in the bumpers to the trailer
hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts,
loosely.
(3) Install the front upper edge to the trailer hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54
N´m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54
N´m (40 ft. lbs.).
(7) Connect the trailer light connector electrical
connection, if equipped.
(8) Connect the license plate light electrical con-
nectors.
(9) Install the license plate.
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
²BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
²DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
²WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
²STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and
later) are not designed for snow plow equipment.The front collision repair tips must not be installed
on any truck equipped with a snow plow, or even
intended to be equipped with a snow plow.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
any holes in the frame that are not specifically out-
lined in this or other, DaimlerChrysler procedure as
frame rail failure can result. When using heat to
straighten frame components do not exceed 566ÉC
(1050ÉF), metal fatigue can result.
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT
FRAME RAIL TIP REPLACEMENT
CAUTION: This procedure is designed to replace
the front frame rail tips that have been damaged in
the crush initiator zones. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (ªframe rackº), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
NOTE: Procedures for 4X2 and 4X4 are common
except as noted in this procedure.
(1) Before proceding with this repair procedure
review the required service warnings and precau-
tions. (Refer to 13 - FRAME & BUMPERS/FRAME -
WARNING)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - REMOVAL)
(4) Remove the bolts and position aside the wire
harness and grounds, if required.
(5) Remove the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- REMOVAL)
(6) Loosen and lower the stabilizer bar mount and
bar. (Refer to 2 - SUSPENSION/FRONT/STABI-
LIZER BAR - REMOVAL)
13 - 4 FRAMES & BUMPERSDR
REAR BUMPER (Continued)

(7) Remove the front cab mount bolt to the Front
End Sheet Metal (FESM) bracket. (Fig. 5)
(8) Make a vertical mark on the inside and outside
face of the frame rail 112 mm (4.5 in.) from the for-
ward edge of the PLP hole in the sides of the rail.
(Fig. 7)
(9) Using a straightedge, connect the two lines on
the top and bottom of the rail.
(10) Using the service tip as a guide, re-check your
cut lines to ensure the service tip will fit when the
cut is made.
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. This
is due to the inaccurate nature of the cut-line and
the fact that the high temperatures achieved duringflame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.
(11) Using a reciprocating saw or equivalent, care-
fully cut and remove the damaged frame rail tip.
(Fig. 6)
(12) Assemble the service sleeve. Refer to SER-
VICE SLEEVE ASSEMBLY at the end of this proce-
dure.
NOTE: Any burned surface coatings will need to be
removed from the sleeve prior to installation and
application of corrosion preventative coatings.
(13) Smooth and square the cut edges of the origi-
nal frame. (Fig. 6)
Fig. 5 REPLACEMENT FRAME TIP
1 - FRONT END SHEET METAL (FESM) BRACKET
2 - CAB INSULATOR
3 - RING-FILLET WELD/HOLE
4 - PRINCIPLE LOCATING POINT (PLP)
5 - WELD ROOT GAP 4 mm-6mm(0.16 in. - 0.24 in.)
6 - FRONT CAB MOUNT BOLT
7 - REPLACEMENT FRAME TIP
Fig. 6 FRAME CUT LOCATION
1 - REPAIR ROOT OPENING
2 - SERVICE SLEEVE
3 - PRINCIPLE LOCATING POINT (PLP)
4 - SUSPENSION BRACKETS
5 - FRAME
6 - FRAME CUTOFF LOCATION - 112 mm (4.5 in.)
7 - FRAME SERVICE TIP
DRFRAMES & BUMPERS 13 - 5
FRAME (Continued)

(14) Dress the cut edge of the existing frame in
preparation for the new rail tip.
(a) Drill four 13 mm (0.5 in.) diameter holes in
the new tip and four more in the existing frame to
accommodate ring-fillet welds. Center these holes
19 mm (0.75 in.) from the cut face of the rail and
38 mm (1.5 in.) from the top and bottom of the rail.
(Fig. 7)
(b) Bevel the edges of the new tip, existing
frame, and ring-fillet holes 25É - 30É. Scribing a
line 2 mm from the cut edge and then grinding
back to the mark will simplify the bevel creation
process and accuracy. (Fig. 8)
(c) Remove any burrs at the holes and beveled
edges.
(15) Dry fit the new rail to ensure alignment and
fit and make any adjustments as necessary.(16) Remove all internal and external OEM e-coat
within 51 mm (2.0 in.) of the weld joint on the
replacement tip and the existing frame rail.
NOTE: Any burned surface coatings will need to be
removed prior to application of corrosion preventa-
tive coatings.
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
Fig. 7 REPAIR SLEEVE INSTALLATION (TYPICAL)
1 - REPLACEMENT FRAME TIP
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - CENTER LINE
5 - LOCATOR LINES (2)
6 - HORIZONTAL WELD HOLE LOCATION - 38 mm (1.5 in.)(BOTH
FRAME SECTIONS)
7 - LOCATOR LINE DIMENSION-2mm(0.08 in.)
8 - VERTICAL WELD HOLE LOCATION - 19 mm (0.75 in.)(BOTH
FRAME SECTIONS)
9 - RING FILLET WELD HOLES
Fig. 8 WELD DIMENSIONS
1 - FRAME REPLACEMENT TIP
2 - FRAME RAIL
3 - FRAME DRESS ANGLE 25É-30É
4 - ROOT PASS
5 - COVER PASS
6 - SERVICE SLEEVE
7 - WELD ROOT GAP 4 mm-6mm(0.16 in. - 0.24 in.)
8 - SERVICE SLEEVE
13 - 6 FRAMES & BUMPERSDR
FRAME (Continued)

(17) On 4X4 models use the service sleeve as a
template to drill a hole in the frame tip to accommo-
date the sway bar mounting bolt. (Fig. 11)
(18) Slide the service sleeve into the replacement
frame tip and align to the 2 mm (0.08 in.) off center
line made previously during the sleeve assembly and
tack the ring fillet welds to hold them in place. (Fig.
9) (Fig. 10) (Fig. 11) (Fig. 12)
(19) On 4X4 models, install the sway bar tapping
plate and secure with tack welds. (Fig. 11) (Fig. 12)
Fig. 9 4X2 SLEEVE INSTALLATION
1 - REPLACEMENT FRAME TIP
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - PLP
5 - SWAY BAR MOUNTING BRACKET
6 - TAPPING PLATE
7 - ROOT WELD GAPFig. 10 4X2 SLEEVE INSTALLATION
1 - REPLACEMENT FRAME TIP
2 - ROOT WELD GAP
3 - SERVICE SLEEVE
4 - SWAY BAR MOUNTING BRACKET
5 - TAPPING PLATE
DRFRAMES & BUMPERS 13 - 7
FRAME (Continued)

(20) Apply ring-fillet welds into the ring-fillet weld
holes on the replacement frame tip (Fig. 13). (Refer
to 13 - FRAME & BUMPERS/FRAME - SPECIFICA-
TIONS - WELDING)
(21) Install the upper FESM insulator onto the
replacement tip and position the service sleeve/re-
placement tip into the existing frame rail.
(22) Loosely install the lower FESM insulator and
cab mounting bolt.
(23) Using the appropriate measuring equipment,
verify the front end sheet metal bracket's location in
all three (X,Y, and Z) planes of space, and adjust if
required. (Fig. 14)
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.(24) When correctly fitted and a weld root gap of 4
mm minimum to 6 mm maximum (0.16 in - 0.24 in)
is established, tack the ring fillet welds to hold the
tip in position, then complete the ring fillet welds.
NOTE: Ring-fillet welds may be filled in with weld
material if an improved cosmetic appearance is
desired.
Fig. 11 4X4 TAPPING PLATE/SLEEVE
INSTALLATION
1 - REPLACEMENT FRAME TIP
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - PLP
5 - SWAY BAR MOUNTING BRACKET
6 - TAPPING PLATE
7 - ROOT WELD GAP
8 - SLEEVE TAB
Fig. 12 4X4 TAPPING PLATE/SLEEVE
INSTALLATION
1 - REPLACEMENT FRAME TIP
2 - ROOT WELD GAP
3 - SERVICE SLEEVE
4 - SWAY BAR MOUNTING BRACKET
5 - TAPPING PLATE
6 - SLEEVE TAB
13 - 8 FRAMES & BUMPERSDR
FRAME (Continued)

SERVICE SLEEVE ASSEMBLY
NOTE: Two sleeve halves are included with each
kit. Modifications as follow, are necessary to create
the correct sleeve assembly for each application.
(1) On 4X2 models, the9lower9sleeve is made by
cutting off the tab and cutting out a notch in the bot-
tom sleeve portion. Round the corners of the cut out
to keep stress cracks from forming. On 4X4 models
the9lower9sleeve is used as provided. (Fig. 15)
(2) On both 4X2 and 4X4 models cut off the front
tab on the upper sleeve portion. (Fig. 16)(3) The sleeve halves are shipped slightly over-
sized to allow custom fitting to each replacement
frame rail tip. It is necessary to grind the mating
surfaces to achieve the desired snug fit into the
replacement tip (rail tube has increasing height rear-
ward of the cut line). Once the two sleeve halves are
fitted, bevel the edges 25É - 30É.
NOTE: Scribing a line 2 mm from the cut edge and
then grinding back to the mark will simplify the
bevel creation process and accuracy.
(4) Remove any burrs at the beveled edges.
(5) Using the Weld Process Specifications table
(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC-
IFICATIONS - WELDING), weld the two halves of
the repair sleeve together. (Fig. 17)
(6) Clean the welds of any flux and other impuri-
ties and grind smooth before proceeding with the
installation of the sleeve.
(7) Find the centerline of the sleeve and scribe a
centerline mark. Mark two additional lines 2 mm
(0.08 in.) on either side of the centerline mark to help
ensure the required 4 mm-6mm(0.16 in. - 0.24 in.)
weld root gap. (Fig. 17)
Fig. 15 4X2 LOWER SLEEVE CUT LOCATION
1 - SERVICE SLEEVE LOWER HALF
2 - CUT DIMENSION 27 mm (1.06 in.)
3 - CUT DIMENSION 36.1 mm (1.42 in)
4 - 4X2 CUTOUT
5 - FRONT TAB CUT LINE (4X2 ONLY)
Fig. 16 UPPER SLEEVE CUT LOCATION
1 - SERVICE SLEEVE UPPER HALF
2 - CUT LOCATION
Fig. 17 SERVICE SLEEVE ASSEMBLY
1 - CENTERLINE SCRIBE MARK
2 - WELD SEAM
3 - REAR TAB (4X4 ONLY)
4 - SCRIBE LINE LOCATION 2 mm (0.08 in.)
5 - FRONT TAB (4X4 ONLY)
13 - 10 FRAMES & BUMPERSDR
FRAME (Continued)