INSTALL INSTRUCTIONS: FRAME REPAIR KIT

Transcription

1 INSTALL OF FRAME REPAIR KIT ( ) Ford Ranger General Tech Tips: Disconnect and Remove Battery Remove fuel tank and clamp, or disconnect fuel lines. Double check for leaking fuel. Ensure fi re extinguisher is available Wear proper safety protection PLEASE WEAR SAFETY GLASSES! Tools required for installation of frame repair kit: 17mm wrench 15mm nut Grinding wheel Air hammer Pliers Permanent marker Tape measure Plasma cutter or cut-off wheel Cutting wheel Flap wheel disc Welding torch Epoxy paint Rust penetrant (optional) 1

2 Instructions NOTE: The photos included show work done on a frame that has been removed from the body. Although this looks somewhat different than work done on a frame attached to the truck body, the steps will remain the same. STEP 1: Remove the truck bed, safely raise the vehicle off the ground, and suitably support the vehicle. NOTE: CONSULT THE VEHICLE S OWNER S MANUAL OR SHOP MANUAL TO DETERMINE THE PROPER WAY OF RAISING AND LOWERING YOUR VEHICLE. STEP 2: If necessary, apply rust penetrant to the bolts holding the shackle to the frame, in order to remove the bolts. STEP 3: Using a 17mm wrench and a 15mm socket, remove the bolts holding the shackle to the frame. 2

3 STEP 4: Using a grinding wheel, grind off the rivets on the top of the frame. STEP 5: Using an air hammer, push the rivets through the frame, where they have just been ground flat on the top of the frame, to make room for the supplied bolts. STEP 6: Using a grinding wheel, grind off the rivets on the bottom of the frame. 3

4 STEP 7: Using an air hammer, push rivets through the frame, where they have just been ground flat on the bottom of the frame, to make room for the supplied bolts. STEP 8: Using pliers, remove the plastic retainer that holds the harness in place. STEP 9: Remove the clip from the frame. 4

5 STEP 10: Using a permanent marker and tape measure, mark off the section of the frame repair kit that needs to be cut to fit on the frame. At the same time, mark on the frame the rust-infected section that needs to be cut and removed as well as the areas that need to be welded, so you can clean to the bare metal for a proper and strong weld. STEP 11: Using a plasma cutter or cut-off wheel, cut the section of the frame repair kit that was just marked for cutting. STEP 12: Using a grinding wheel, clean away the slag on the frame repair kit to make it ready for welding. 5

6 STEP 13: Pull harness away from cutting area on the frame. STEP 14: Using a cutting wheel, cut away the rust-infected area of the frame that will be replaced with the frame repair kit. STEP 15: Using a flap wheel disc, sand the inside and outside of the frame to clean for welding. 6

7 STEP 16: Place the frame repair kit on the frame, and place the washers between the frame and the repair kit on the top and the bottom. STEP 17: Place nuts and bolts in the top and bottom of the frame repair kit where it mounts to the frame. STEP 18: Using a 17mm wrench and a 15mm nut, attach the nuts and bolts to the frame. 7

8 STEP 19: Using a welding torch, weld the repair kit to the frame. 8

9 STEP 20: Spray epoxy paint to the weld to prevent any further rust. STEP 21: Reinstall shackle bracket, suspension components, bed, and any other parts removed for installation. See Dorman part# & for new brackets and shackles. STEP 22: Safely lower the vehicle. NOTE: CONSULT THE VEHICLE S OWNER S MANUAL OR SHOP MANUAL TO DETERMINE THE PROPER WAY OF RAISING AND LOWERING YOUR VEHICLE. We appreciate your opinions regarding this product! Please call our Technical Assistant with any challenges or suggestions regarding the installation or operation of this product