B. No Cracks Found -- Weld Frame

IMPORTANT:
All welding must be performed by a qualified welder.

WARNING:
PROPER CLOTHING, FACE SHIELD, RESPIRATOR AND HELMET SHOULD BE USED FOR PERSONAL PROTECTION. IN ADDITION, FENDER COVERS TO PROTECT THE PAINT AND WELDING FIRE BLANKETS SHOULD BE USED IN THE ENGINE COMPARTMENT TO PREVENT ANY DAMAGE DURING REPAIRS.





1. Bolt the template from the Special Tool Kit (Miller Special Tool # 8196) on the top right corner of the lower cross member to locate the two (2) pilot hole locations. Use the bolts supplied in the kit to attach template to lower radiator cross member and center punch the holes. The template is marked TOP (Fig. 10).

2. Remove the template and drill two 2.5 mm (3/32") pilot holes. Drill through the top layer only.





3. Use the 14 mm diameter Roto Broach from the Special Tool Kit to remove material around the two pilot holes in the cross member. The lower cross member overlaps the right frame. Drill the top layer of the lower cross member ONLY, creating a weld access hole (Fig. 11).





4. Prepare welding area using a grinder, drill with a wire brush, or other tool, to insure area to be welded is clean (Fig. 12).

5. Cover the engine compartment and painted surfaces with a welding cover to protect the engine compartment and painted surfaces during welding.





6. Fusion weld both sides of the slot to the steering gear inner reinforcement (bottom of the slot). This weld attaches the steering gear inner reinforcement to the frame and the lower radiator cross member. Completely weld slot full (Fig. 13). All welds must be made with a MIG welder and steel welding wire, shielding gas required is a 75% Argon and 25% CO2 mix.

7. Allow the area to cool, and apply black primer, or undercoating, on all exposed surfaces.

8. Install steering gear using the new bolts supplied in the kit (PN 5003299AA) and torque to 95 N.m (70 ft lbs.).

9. Continue with Section D.