Hydro Form Frame Repair

[97-78 Diesel Crew]

Can the 03 04 frames be straightened or must they be replaced?



The frame in question is pushed in on the drivers side where the center post for the rear door is attached. It is very close to the fuel tank.



Have been told by the dealer that they are not to be repaired but replaced.



I can't find anything authoritative on this.



Anyone know ??????



Thanks

 

[wsurf]

I would suspect that the hydro formed frames are thinner and stronger than the typical channel used in most trucks and if returned to original position might cause it to crack. Again only speculation. Material is stronger that the channel frame due to the forming process (work hardening).

 

[Casey Balvert]

Check the Shop Manual. Some minor repairs are allowed but I believe any major damage results in a frame replacement.



Casey

 

[Joseph Donnelly]

The Service Manual gives procedures. It says how to weld, not to use a torch to cut, etc.

 

[rbattelle]

The small wall thickness on these frames is too sensitive for major repairs. Once it's been stressed beyond yield, it'll never be of the same strength. If it were me, I'd weld reinforcements all over the area where the bend occured.