a. Slide the bolt and washer into the "window" opening on the outside of the frame siderail, and insert it into the newly-reamed hole.
NOTE:
ON VEHICLES WITH QUAD SHOCK ABSORBERS, IT MAY BE NECESSARY TO REMOVE THE SHOCK/SPRING TOWER TO GAIN ACCESS TO THE "WINDOW" IN THE SIDERAIL.
b. Install the washer and nut and torque nut to 190 ±4N-m (140 ±3 lb-ft). Turn the wheels lock-to-lock several times to seat the joint and retorque. Tack weld the nut to the bolt after tightening.
CAUTION:
DO NOT WELD THE NUT/WASHER TO THE FRAME.
NOTE:
ON HEAVY DUTY VEHICLES, IT MAY BE NECESSARY TO UPGRADE THE REPLACEMENT FASTENER TO A 5/8" GRADE 8 TORQUE PREVAILING NUT (34991-S2), BOLT (58720-S100) AND TWO (2) WASHERS (44881-S2) TORQUED TO 250 ±6.8 N-m (185 ±5 LB-FT).
(B) Other #1 Crossmember Rivets
NOTE:
USE WARRANTY DEALER CODING: 5020, AS BASIC PART NO.
Follow the "Huck Fastener"/Repair Procedure A, listed in this article for cold head rivets and replace the rivet with a 9/16" Grade 8 torque prevailing Nut (34990-S2) with a Washer (44880-S2) and a Grade 8 Bolt (58698-S2) with a Washer (44880-S2).
(C) Other Rivets
NOTE:
USE WARRANTY DEALER CODING: 5004, AS BASIC PART NO.
Follow TSB «96-15-11» for proper rivet replacement procedure.
(D) Transmission Crossmember
NOTE:
USE WARRANTY DEALER CODING: 5060, AS BASIC PART NO.
This procedure should be done on flat ground or on a drive-on lift, with the wheels pointed straight and full weight resting on the wheels.
NOTE:
A SIMILAR NOISE CAN OCCUR AT THE TRANSFER CASE SKID PLATE ATTACHMENTS AND SHOULD BE INVESTIGATED IN CONJUNCTION WITH THIS REPAIR PROCEDURE.
1. Remove transmission weight:
a. Remove bolts attaching transmission mount to the crossmember.
b. Lift the transmission to remove any load to the crossmember. The crossmember should now be completely loose.
NOTE:
YOU MAY NOTICE THE FRAME RAILS TWIST SLIGHTLY AND "RELAX" AFTER THIS NEXT STEP.
2. Loosen crossmember:
a. Loosen all bolts attaching the crossmember to the frame siderails.
b. Loosen all bolts attaching the crossmember gusset(s) to the crossmember and to the frame siderails. The crossmember should now be completely loose.
3. Turn the steering wheel lock-to-lock and then straighten the wheels. This helps to remove any stress in the frame.
4. Install new crossmember fastening hardware one at a time and replace each nut and bolt with a new Nut (N800937-S427) and Bolt (N802114-S2) and leave them loosely assembled until all crossmember and gusset fasteners have been replaced.
NOTE:
IT IS IMPERATIVE THAT THE FOLLOWING TIGHTENING SEQUENCE BE FOLLOWED.
5. Secure the crossmember attaching hardware. Determine which style of crossmember the vehicle is equipped with, and follow Step 6 or 7.
6. If the vehicle has a wraparound-style crossmember (Figure 7), torque each grouping of fasteners in the order listed in the following Substeps to 70 ±10.5 N-m (52 ±8 lb-ft).
Click "Next" beside the image above to continue.
See also:
http://www.nloc.net/vbforum/gen-1-lightnings/209927-frame-off-resto-225k-mile-lighting-2.html#post1958385
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