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Broken Frame! 89 W350

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I was out in Nevada last month supporting radio communications for an offroad race and noticed that the Alaskan camper mounted on my '89 W350 (11,000 GVW)seemed to be rocking unusually close to the front cab. I stopped the rig for a closer look. To my great amazement, the truck frame was broken (and physically separated!)ON BOTH SIDES directly above the axle and midpoint between the rear spring perches.
With the help of my pry bar, steel wedges and numerous 2X4's, I drove the 18 miles through Bullfrog into Beatty, Nevada and employed a welder to put a temporary fix in place so I could get home. Three hours and $150 did the trick.
Several local people watching the repair mentioned that they have seen this identical problem with Dodge 1 ton frames that were used by the local mining companies.
My truck started out life as a cab/chassis. A utility bed was installed by the previous owner and I installed my 30 year old Alaskan over the utility bed. Dodge listed the GVW @ 11,000#. It scales out at 9810# fully loaded (FIVE TONS OF FUN!). I haven't jumped any canyons with it but it spends a lot of time on the dirt roads and 4x4 trails.
I noticed that Dodge punches an oblong hole in the frame at the point where the fracture occurred. An ideas why they could do that?

Has anyone else experienced a broken frame?

Now I need something more permanent. Any suggestions out there in the forum?

1. I was thinking of "boxing" the frame in that area and maybe putting some plates welded on the frame face over the fracture point
2. Would a set of "bladder" type air shocks or springs be appropriate?

Thanks for any suggestions

DesertRat
 
Yes, I would put plates on both sides if you can and box or join them on the top and bottom if possible. I prefer to overengineer frame repairs, because if it doesn't hold you could have a bigger mess. One suggestion I have is to make several 3/8" to 7/16" holes in the steel plate that goes on the outside (flush side) of the frame. Then once it is welded in place, I would fill the holes with a weld. This will join that plate with the frame much better than just welding the edges.

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99 2500 QC, LWB, 5spd, 3. 54 limited slip, Intense Blue, 275HP Injectors
Tow Lite trailer
96 KTM 360 EXC
99 Durango 4x4 360cid
 
I would have a piece of channel bent to fit over the frame or inside of the frame. Have the ends cut at an angle to distribute the load. You do not want to weld at 90 degree angles to the frame. (staight up and down) If you box it you might make the frame to rigid and it will brake again. Just a thought.
 
I tend to agree with GentleBen, the frame needs to flex somewhat. The beefing of the beams with C shape sounds like a good fix.

Jason
 
Man oh Man, it seems like everytime I turn around its another cracked Dodge truck frame. I have a '95 2WD 3500 dually CTD fractured on the IFS spring tower, Dodge has had it for more than three weeks! They don't know what to do! I have posted this on TDR nobody seems to have a clue.

On yours, I would "sister" the broken area and ONLY weld lengthways, NEVER across as you will "invite" a crack. I am a Machinist/equipment mechanic and am starting to wonder about Dodge truck frames.
 
Now you guys are getting me worried, maybe it would help if I de-bomb a little.

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1972 Chinook class C with 96/215 5spd, 4/5" exh, 4"BD, MagHytec, 85gal fuel, K&N RE0880, AutoMeter, 370's, BD gov kit, BD afc kit, 16cm, 16%btdc, yada-yada-yada
www.fostertruck.com/cummins
 
From what I understand, Dodge used more rigid frame alloys than the other two. Sometimes, in applications that stressed the frame constantly, the frame could crack.

I'd not be too worried, just, if you ever "thump" the truck really hard, get it checked out for cracks. My old D150 had a cracked frame too, but it got hit so hard the back of the bed and the cab deformed each other...


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Mark Koskenmaki
 
Desert Rat,

There is a post in "General Diesel Forum" about cracked frames.

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Stan
93 2WD extended cab, Banks Power Pack, K&N Air Filter, PW Injectors,Auto w/4. 10 rear with limited slip, US Gear Exhaust Brake, 31/2" Exhaust, 5K air bags, Boost/Pyro/Tach Gauges, Green/Silver, new 40-20-40 bucket seats, 149K
 
I don't get it!
Grandpa had a 1st Gen club cab camper special with a 360 that he hauled a MONSTROUS Holiday Rambler slide in with! Then he overloaded it with feed bags to the top of the 30" racks, about once a month.
He never missed a curb or a ditch, and that frame is still A-1!

I wonder if they changed steel suppliers, just like they did with hitches in 98?
Gene
 
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