2nd Gen Non-Engine/Transmission Cracked FactoryWelds in Frame

[surfbeetle]

I was changing the starter contacts this weekend and while under the truck, noticed that on the driver's side where the boxed frame meets the C portion of the frame that the welds were cracked. The actual frame was fine. This was located right at the point where the Transmission Crossmember is bolted to the frame, under the driver's door, and as I said where to the two different types of frame pieces meet. All other welds appeared to be fine. I had a friend just re-weld the factory welds. Any thoughts on what would cause this? Also, should I have done any further re-inforcing? I know frame welding is frowned upon. Thanks in advance for your input.

I attached a photo. The vertical crack is to the left of the vertical red line and the horizontal line is next to the other crack.

 

[McCRam]

Going to have to crawl under my truck tomorrow

How many miles are on your truck? Do you use it hard? Let us know how the fix goes.

 

[surfbeetle]

138000. I am the original owner. Its a daily driver, I have pulled a 5,000 lbs. fifth wheel for the last three years and a 3,000 lbs. before that when I camp on average of 2 to 3 times a month in the summer. One time, I hauled about 5 loads of fill dirt, each load was less than 2 or 3 Bobcat buckets full. I didn't want to overload the truck. For the most part, the truck is empty or has a surfboard in it. I don't think that I have been hard on it, that's why I was surprised to find the weld had cracked.

 

[Jschafer]

My truck had a recall back in 95 or 96 for inspection of the welds and install some stiffeners but they were near the front spring perches, my truck had not cracked but they welded on the stiffeners

 

[surfbeetle]

I knew about that recall. That was for the front shock towers. It only applied to 4x4 2500's and 4x2, 4x4 3500's. Mine is only a 2500 two wheel drive so I never got recalled on that one. I realize it's a ten year old truck, but I have a 40 year old volkswagen bug that is still in one piece with close to 300,000 miles on it. I guess I expected the truck to have been better built than it is. They just don't make anything like they used to.

 

[JFaughn]

From what I can see the robot welder may have been a little off to one side and got poor penitration , now I haven't got my glass's on and I'm looking at a picture. You shouldn't be able to see the origanal end of the frame only a bead of the weld.

 

[Joseph Donnelly]

Reweld. Also you might get the 98-up heavier crossmember to add stiffness there. Be sure the bolts for the crossmember are tight and use factory flange head bolts and nuts or add grade 8 washers. The recall to reinforce front spring perches on 4x4 up to about 1996 should be followed. In rare cases the upper spring perch cracks loose.

 

[Gary - K7GLD]

I knew about that recall. That was for the front shock towers. It only applied to 4x4 2500's and 4x2, 4x4 3500's. Mine is only a 2500 two wheel drive so I never got recalled on that one. I realize it's a ten year old truck, but I have a 40 year old volkswagen bug that is still in one piece with close to 300,000 miles on it. I guess I expected the truck to have been better built than it is. They just don't make anything like they used to.

Dunno - I hear that quite a few of those VW frames crack regularly too...

 

[surfbeetle]

Gary, you know that with abuse anything will crack, but I don't feel that the truck has been abused. I guess I am still stuck on the idea that a truck that is only 10 years old should not have had this failure unless it was mistreated. Oh well, live and learn. I just hope the '05's fare better, my brother in law just bought one.