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GROUP-1
BODYAND _ FRAMEALIGNMENT CONTENTS SPECIFICATIONS . . . . .. .. .. . . . . .. .. . . . . .. .. .. .. .. . . . . . . . . . . . . . . GENERAL SPECIFICATIONS . . . . . . . . . .. . . . .. . . . . . . . . TORQUE SPECIFICATIONS . .. . ..*...........*....... 2 2 2 2 2 MEASUREMENT MEASUREMENT FRAME ALIGNMENT METHODS POINTS . . . . . . . . . .. .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . .. . 2 3 3 . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BODY DIMENSIONS AND MEASUREMENT METHODS . . . . . . . ..*.............................*................... HOW BODY INDICATED DIMENSIONS ARi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .
13-1
K?
t-l
GENERAL
"
BODY~MENSI~NS
SPECIFICATIONS/ AND MEASUREMENT /
METHODS
SPECIFICATIONS
Frame Type Sectional form TORQUE SPECIFICATIONs
Ladder type Box type Nm (ft.lbs.) loo-120 (72-87)
Front suspension crossmember to support bracket
EIO~;~;~ENSIONS
HOW BODY DIMENSIONS
AND MEASUREMENT
ARE INDICATED :
Projected
dimension
Projected dimensions These are the dimensions measured when the me,asurement points are projected into a reference plane, and are the reference dimensions used for body alterations.
Probe
F1812E
MEASUREMENT
METHODS
(using a tracking
gauge)
1. How to measure projected dimensions If the length of the tracking gauge probes are adjustable, make the measurement by lengthening one probe by the
amount equivalent to the difference in height of the two
Hole center
surfaces. 2. If hole diameters are the same and the probes are conical, insert the probes into the holes, and then make the measurement. This method of measurement should be used if the diameters of the holes in the location to be measured are the same. 3. If hole diameters are different, or if the' probes are
pointed, measurement from the hole centers is impos-
F1813C
sible. The circumferences must be used instead.
How to Determine Desired dimension Dimensions :
Example: Reference dimension: Measurement hole diameters:
Desired dimension:
13-2
I 2 = 600 (23.6) D = 20@(.79), d = 104 (.39)
L = 600 (23.6) + 2"`;
mm (in.)
l"(#J
= 605 (23.8)
BODY DIMENSIONS AND MEASUREMENT FRAME ALIGNMENT
MEAS.UREMENT
point)
METHODS/
b-I -mm
POINTS
("P"
indicates
the measurement
Hole
centers
Hole
circumferences
I
Measurement points are determined as follows: 1. If the measurement is to be made from the hole centers, the point at the surface from which the measuring instrument is applied is the measurement point. 2. If the measurement is to be made from the circumferences of the holes, the point at the hole circumference of the surface from which the measuring instrument is applied is the measurement point.
F1813:
FRAME ALIGNMENT
COMPONENTS
1. 2. 3. 4. 5. 6. 7. 8. Body mounting bracket .Differential mounting bracket Engine mounting bracket Support bracket Side frame No. 4 crossmember Rear shock absorber No. 6 crossmember Nm A 100-l 20 ft.lbs. 72-87 9. 10. 11. 12. 13. bracket, right 14. 15. No. 5 crossmember dear shock absorber Front suspension No. 1 crossmember Lower arm bracket Stabilizer bracket Towing hook bracket, crossmember 1 ? left
Projected
Dimensions
Es? P-4
FRAMIE ALIGNMENT
mm (in.)
enter
of front
bumper
mounting
hole
Center
of body
mounting
hole
enter ale
of differential
mounting
bracket
;;;ter of steering gear box mounting
15w5051 of lower arm (front) mounting hole :enter of upper arm mounting hole
Center
Center
of lower
arm
(rear)
mounting
hole
enttir
of body
mounting
hole
13-4
FRAME ALIGNMENT
15w510 Center hole of No. 2 crossmember mounting :enter iole of rear spring (front) mounting enter of body mounting hole
15w51:
m
enter hl ale of rear spring shackle mounting
15w51:
I Center of body mounting hole enter of torsion ing hole bar anchor arm mount-
I\
Center (L.H.) of shock absorber mounting end
\
absorber mounting end
15W516 Center of body mounting hole
F;n$r of shock . .
13-s'
iis?
FRAME ALIGNMENT
: INSPECTION 1. Check crossmembers for cracks or damage. 2. Check crossmember as illustrated for dimension;. (15W521) -.
Ii
.j---,,,2
mm (jr4
15w52
3. Check the side frames, crossmembers, and brackets for cracks or separated welds, by tapping them with a test ham,mer. (15W5 18) If in doubt, polish the. frame surface well and check it with a crack detecting agent (liedcheck, etc.). 4. Check the frame for bends and distortion. `-- Correct if not within specifications. . .I
INSTALLATION 1. Install the front suspension crossmember. , NOTE -' It isimportant that the bolts be installed from therear. .`. .' 3: (15W519) 2. When replacing the floor plug, be sure to apply an appropriate amount of semi drying sealant.
REPAIR When a crack is found in the frame, it should be repaired as follows: 1. Using a 6-8 mm drill, drill a stop hole at a point l-3 mm (.04-. 12 in.) from each end of the crack. 2. Countersink each hole with a 1O-l 2 mm (.4-.5 `in.) drill.
l-3 (.04-.12)
1-3 (.04-.12)
@ -3Lyl-Liyp
ho,e
10-12
(.4-.5)
mm
(in.)
s15003
13-6
FRAME ALIGNMENT
3. Make a groove along the crack by using a chisel or gouge. 4. Fill the groove and the stop holes completely with 2-3 -layers of electric-arc welding.
L,A
90"
8 f.31) ,041
Section mm (in.)
A-A S15506
5. Finish the welded area with a grinder.
Caution Do not use gas welding; doing so could cause distortion. Use care to prevent thinning the frame itself by excessive grinding.
6. Make a patch of an angle steel stock as illustrated. (15S511) 7. Use an angle steel stock of the same material and thickness as frame. 8. To prevent stress concentration on the patch, make sure that its corners are cut away obliquely. 9. The patch should be long enough so that the ends properly extend beyond the crack. 10. Make sure that edges of the patch are not positioned near spring hangers, crossmember ends or other points subject to concentrated loads.
D 30-45"
l!iSSll
11. Arc weld the patch at points about 10 mm (.4 in.) from the crest of the patch to avoid stress concentration. (D15507) 12. Clean the welded area and apply chassisblack.
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