Standard Procedure - Front Frame Rail Sectioning Procedure

WARNING: This page is about a different car, the 2012 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Damage to the frame rail, rearward of the area covered by this procedure, which is not eliminated during preliminary structural corrections and pulls, necessitates complete rail replacement to restore the vehicle to pre-loss condition.

Fig 1: Identifying KK Frame

Courtesy of CHRYSLER GROUP, LLC

1 - RIGHT FRAME RAIL

2 - LEFT FRAME RAIL

With vehicle mounted to appropriate pulling and 3-dimensional measuring equipment, complete the following procedure paying particular attention to body dimensions while fitting and welding panels.

Remove bumper components, cooling module, headlamps, and all other components for clear access to repair area.

Fig 2: View Of KK Frame

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1 - SMALL HOLE

2 - SCRIBE MARK

3 - RADIATOR SUPPORT BRACKET

4 - RADIATOR SUPPORT BRACKET

5 - SCRIBE MARK (TRANSFER FROM OUTER FRAME RAIL) - INNER FRAME RAIL

6 - DISTANCE 93 mm (3.5 in.) - OUTER FRAME RAIL

Using the center of the small PLP hole on the outer side member as reference, mark outer rail at top and bottom then create vertical scribe mark 93 mm (3.5 in.) forward of the PLP on outer frame rail.

Fig 3: Locating KK Frame

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1 - VERTICAL SCRIBE MARK

2 - OUTER FRAME RAIL

3 - MEASURE FORWARD 38 mm (1.5 in.)

4 - MEASURE REARWARD 38 mm (1.5 in.)

Using the scribe mark on the outer side member as reference, measure rearward 38 mm (1.5 in.) and forward 38 mm (1.5 in.) and mark outer rail at top and bottom then create vertical scribe mark on outer frame rail.

Fig 4: KK Frame (4)

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1 - REMOVE WELDS

2 - OUTER FRAME RAIL

3 - REMOVE WELDS (Z-REINFORCEMENT)

4 - REMOVE WELDS

Remove welds holding the inner and outer side members together between the two scribe lines on the outer rail.
Remove the welds holding the internal Z-reinforcement to the outer rail between the two scribe lines.

Fig 5: KK Frame Location
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1 - OUTER FRAME RAIL

2 - CUT AND REMOVE

Carefully cut the outer side member top to bottom at the scribe lines without damaging the inner side member or the Z-reinforcement inside the rail and remove the access panel or "window".

Fig 6: KK Frame

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1 - TAPPING PLATE

2 - CUT AND REMOVE

3 - INNER FRAME RAIL

WARNING:

Do not cut tapping plate (1).

Using a reciprocating saw, cut vertically down through the inner frame rail and Z reinforcement at the scribe location on the inner rail.

Fig 7: View Of KK Frame Location

Courtesy of CHRYSLER GROUP, LLC

1 - EXISTING FRAME RAIL

2 - INNER FRAME RAIL

3 - REPLACEMENT FRAME TIP

4 - Z-REINFORCEMENT

5 - ACCESS WINDOW

Carefully clean and de-burr all cut edges and prepare for welding.
Remove any paint, e-coat, or other coatings within 25 mm (1 in.) of any weld area.
Using the same procedures previously described, prepare the service rail tip for installation.
Fit and position the new rail tip to the vehicle using XYZ dimensions and measuring equipment.
Confirm good joint fit-up with inner frame rail and Z-reinforcement and root gap equal to width of saw cut.
Tack weld the new tip into position using the weld chart located at the end of repair procedure information.

Reconfirm proper tip location.

Fig 8: KK Frame

Courtesy of CHRYSLER GROUP, LLC

1 - Z-REINFORCEMENT

2 - REPLACEMENT FRAME TIP

3 - ACCESS PANEL

4 - ACCESS WINDOW

Weld inner frame rail in the following sequence.
1. Upper half from the access window.
2. Lower half from exterior of rail.
3. Clean backside of above two welds in preparation for welding.
4. Upper half from exterior.
5. Lower half from access window.
Weld Z-reinforcement from top and from bottom, from inner side rail to outer side rail.
Prepare access panel for reinstallation.
Clamp the access panel back to rail assembly.
Weld the butt-joints completely using a skip/stitch method to reduce the heat affected zone and distortion.
Weld the access window at the top and bottom to the inner frame rail using ring filet or Squeeze Type Resistance Spot Welding (STRSW) (puddle) welds.

Install clamp to snug gap between outer rail and inner Z-reinforcements and MIG weld the outer rail back to the Z-reinforcement through the slots in the outer rail.

Fig 9: KK Frame Identification

Courtesy of CHRYSLER GROUP, LLC

1 - RIGHT FRAME RAIL

2 - LEFT FRAME RAIL

3 - CLEAN AND REFINISH REPAIRED AREA(S)

Clean all repaired areas and apply appropriate refinish and corrosion protection material.
1. Apply rust protection into the repaired frame rail.