Holes Drilled - Will My Truck Break in Two?

[JDeMont]

Re: Drilling Holes in a 3rd. Gen Frame.



I don't think I knew it before April of 2004 when I had my 5er hitch installed, but I have seen references since then including the current TD Register. Ninnyhow, if it's an absolute no-no, the RV Store should have known better as mine is a 2004. 5 and the restriction should have been out over a year.



I don't think there's a problem to date, but what should I look for? Anyone experience failure or is the concern overblown?



Thanks,



2005. 5 White Laramie Quad Dually, 6 Spd, 4:10, Pac Brake, SS Wheel to Wheel Nerfs. Stocker than Snot. No Gauges - too much Information

 

[MikeBeggy]

My 1 cent worth, in todays world of lawyers and lawsuits, if someone mistakenly or otherwise drilled your truck frame, they have violated a very basic engineering rule that modification of factory designs will put the liability of failure on the owner and no longer on the manufacturer. It's long been discussed in service manuals to never drill, cut or weld to any vehicle frame. Imagine the legal implications if your trailer broke free of your truck (at the drilled holes in the frame) and ... ... . the rest of it. Would it really happen, could it happen, is it worth the risk?

 

[RJOL]

Here is the TSB that covers this issue... Have fun...



http://www.dodgeram.info/tsb/2003/13-001-03.htm

 

[rbattelle]

In my opinion, the most important question to ask at this point is whether they installed anti-crush sleeves (is there an official name for these?) in the frame when they passed the bolts through. If they failed to do so, it's quite possible that the frame was crushed either during the install or later in use.



-Ryan

 

[Bertram65]

As long as the holes are within the guidelines of the TSB you have nothing to worry about, I drilled 4 holes in my frame when I installed my 5th wheel hitch. You only need the crush sleeves if the bolt passes from one side of the frame to the other.

 

[Dean Upson]

I had the same concerns about drilling. This information comes a bit late, but PullRite makes a great no-drill, no-weld hitch. See this month's TDR. Casey Balvert, Fireman and I did a report about a year and a half ago on the PullRite.



Dean

 

[rbattelle]

You only need the crush sleeves if the bolt passes from one side of the frame to the other.

I had assumed this was the way the hitch was installed... is there a way to bolt into only one side?



-Ryan

 

[SRadke]

is there a way to bolt into only one side?



-Ryan

Yea, I did it with my running boards. You can use a bolt with a finger on it and a hole that is large enough you can slip the bolt in at an angle then straighten up and pull. I used existing holes but I suppose you could make the hole if need be. I should also note that I'd be hesitant to use this method on something as important as a trailer hitch. Running boards are one thing but you don't want your trailer hitch wiggling loose.



-Scott

 

[Bertram65]

I had assumed this was the way the hitch was installed... is there a way to bolt into only one side?



-Ryan

Yes, for the Reese under bed mount for the Signature series hitch you drill a 21/32" hole in the outside frame wall and then using the special supplied 30" wire you thread the special bolt into it, fish the wire to the hole from an existing hole that is about 20" further back on the frame and then gently pull the wire and subsequent bolt through the hole. Then you have to hold the bolt while you thread on the nut, this is tricky as the bolt is only sticking out about 3/8", it is also tedious because if you drop it back into the frame there would be no way to retrieve it. Of course no extra bolts are included. The special bolt is splined on the shoulder next to the head, as you tighten it the splines cut into the edge of the hole in the frame locking it in place. The bolts are tightened to 170ft/lbs of torque.

I can see where an installer may take the easy way out by either drilling a hole on the inside of the frame close to the hole for the bolt, of course it would have to be large enough to fit the head of the bolt so it would be larger than allowed by the TSB or they could through bolt it through both sides of the frame so they did not have to deal with the tricking fishing part.

The frame bolts and having to cut four 2. 5" holes in the bed were the worst part of the install, screw up the bed holes and it would be very hard to make it right.

 

[Lorenz]

Any pictures of these bolts or sleeves? were can i find some

 

[klenger]

See page 20 at http://www.klenger.net/dodge/pullrite/superrail-instructions.pdf

 

[Bertram65]

Any pictures of these bolts or sleeves? were can i find some

This is the best I could come up with.

 

[JHardwick]

Re: Drilling Holes in a 3rd. Gen Frame.



I don't think I knew it before April of 2004 when I had my 5er hitch installed, but I have seen references since then including the current TD Register. Ninnyhow, if it's an absolute no-no, the RV Store should have known better as mine is a 2004. 5 and the restriction should have been out over a year.



I don't think there's a problem to date, but what should I look for? Anyone experience failure or is the concern overblown?



Thanks,



2005. 5 White Laramie Quad Dually, 6 Spd, 4:10, Pac Brake, SS Wheel to Wheel Nerfs. Stocker than Snot. No Gauges - too much Information

Yup!! It's now officially junk! You take a welding rod or a drill bit to a hydroformed frame and you just ruined a $40,000 vehicle :-laf

 

[Greg Boardman-RIP]

How about a plasma cutter, grinder and tig welder... ... The go 80 mph through the desert, over whoops, and hit a 75 foot kicker at speed. Does it break, no!!!! This truck is built by Diamler not chrysler. It is a German Tank!!!! Do not worry about some stupid TSB or anything else. Three holes on one side of your frame will not hurt it. Will DC deny warranty if it snaps in half... ... ... . Probably...



Greg

 

[J&LRam]

JDeMONT

Way overblown concern.

The welders that weld for two national brands of utility/stockman truck bed for dealers in my area think the hydroformed box frames on our Dodges are better to weld on because their only welding on one side of a box.

My hitch for my 5er,12000 lb, was welded two years ago in my '03. The hitch on my neighbors '03 3500 ,goose neck hitch, was welded on 180000 mi ago and he pulls in excess of 26000 lbs [hotshoter].

I saw a 35 ft 5er at my RV dealers last week that hit black ice on I-44 east of Tulsa, jack knifed , the 5er hitch pin box was pulled out of the 5er frame. The dooly that was towing it had a crushed cab and right side bed destroyed. The Reese hitch was bolted in to the frame and couldn't tell that it had been wrecked. Follow the Dodge Body Builders Guide for welding/drilling ... ... ... ... ... JIM

 

[rbattelle]

Greg makes a good point, and speaks from experience.



-Ryan

 

[JimBob24]

J&L Ram is right. There is potential for problems if done incorrectly, but DC never says not to do it. They say that they "do not recommend it", then, in the same TSB, they tell you how to do it correctly!!! It really is a common sense issue.



Jim