2nd Gen Non-Engine/Transmission frame cracks

[Mechaneck]

I am a mechanic for a city shop, we have several 3/4 and 1 ton Dodge gassers. During a PM I noticed a small crack (approx. 3/8" long) at the welds between the frame and the core support, the truck was still under warranty so it went to the dealer. They noted it in case it developed, but didn't feel it was worth messing with at this point and that they had not seen this before. At this point they are very fine and do not seem to be growing.



Since then I have seen the same small cracks on nearly every one of our Dodges that have come in. Is this a fairly common thing on these trucks?



Does it develop into a problem?



Thanks,

Keith

 

[dresslered]

Any way we could get some pictures of these. I have heard of a few incidents, but usually there was some other reason for the cracks. I will check mine out thoroughly as I frequently carry a 5000-lb slide-in.

 

[ToolManTimTaylor]

I thought that was an early 2nd gen issue and if memory serves me right there was a member that had his entire frame assy replaced at the dealer. Body off drivetrain swapped cost some rediculous dollars.

 

[ToolManTimTaylor]

Spring perch cracks and such

https://www.turbodieselregister.com/forums/showthread.php?s=&threadid=1165





https://www.turbodieselregister.com/forums/showthread.php?s=&threadid=20008



<hr>

First Gens .....





https://www.turbodieselregister.com/forums/showthread.php?s=&threadid=43677





https://www.turbodieselregister.com/forums/showthread.php?s=&threadid=26820

 

[krs]

"During a PM I noticed a small crack (approx. 3/8" long) at the welds between the frame and the core support

Can you define "core support"? Where are the cracks?

Though you don't identify the year(s) involved, a quick review of TSBs and recalls for late 2nd gen trucks didn't turn up anything that sounds close to what you describe so your dealer may be truthful in saying he hadn't seen it before.

There is something about creaks in the L/H dash being related to cracks in welds at the top side of the firewall...

 

[Gary - K7GLD]

Do the gas rig use the same frame as the diesels? I thought the Cummins came with a "special" frame - and yeah, I would like to know exactly where to look as well...

 

[ToolManTimTaylor]

Well the only TSB/Recall I could find: .... If he has a 1995 or before

Models: 1994-1995 (BR)

· 2500/3500 Series 4x4 Regular and Club Cab Dodge Ram Trucks

· 3500 Series 4x2/4x4 Chassis Cab Dodge Ram Trucks

NOTE: This recall applies only to the above vehicles equipped with a 5. 9L diesel or an 8. 0L V-10 engine ("C" or "W" in the 8th VIN Position) built through:

· March 21,1995 (MDH 0321XX) for Regular Cab Ram Trucks.

· June 3, 1995 (MDH 0608XX) for Club Cab Ram Trucks.



Repair: Both front coil spring towers must be inspected for cracks. Trucks without cracked towers must have a coil spring tower reinforcement bracket welded onto each existing coil spring tower. Trucks with a cracked right and/or left coil spring tower must have the cracked coil spring tower(s) replaced in addition to welding on the reinforcement brackets. All welding must be performed by a qualified welder.







Here is a link to the NTSB's Actual documents



http://152.122.48.13/prepos/files/Artemis/Public/Recalls/1999/V/RCDNN-99V214-4069.pdf

 

[Mechaneck]

I chose a poor term by using core support, as on a non-unibody vehicle it is not actually the core support, but the forward most cross-member under the radiator. The cracks are pretty small 3/8" to 1/2" long, and not seperating, just visible as a rust line. They are actually cracks, you can feel them with your fingernail.



They are on the inner part of the frame on the bottom side at the welds to the front c-member.



The 2 trucks I had in the shop today that had them were a '98 3/4 ton with a service body, and an '01 1 ton dually with a dump box. Both are 2WD with 5. 9L V8's. Some of the others are straight pick-ups, not sure of the years.



I started to track them today to see which all models are involved. I'll take my camera and see if I can get some pics, hopefully we'll have another one in soon. I'd hope to be able to get some up sometime this week, assuming I can figure out how to post them?



The 1 ton I looked at today was the first one I found in Dec. They don't seem to be getting any bigger and aren't really a structural concern at this time, but there must be a reason they are cracking??



Keith

 

[dresslered]

Looking forward to seeing the pics. Kind of worrisome for those of us that have a winch mounted up there. If you have trouble posting them (i. e. sizing them so that they are allowed on this board), you can send them to me.

 

[Gary - K7GLD]

Looks like this potential problem would only apply to heavily used rigs, probably ith big heavy stuff hung off the front, like winches, blades and such - unless that area also sees heavy torque frame twisting from other loads such as towing heavy...

 

[jrobinson2]

Found one

I have a small crack on the drivers side were the inside frame section meets the front crossmember, about 3/8" long. Truck is a '99 4x4 with 104000 miles, no heavy towing, no snowplow, no winch, occasional off road use. It doesn't look too serious, just one more thing to watch

Jared