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Group 41
Frame
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Pub No. TWSE9501-41

 41

GROUP 41 FRAME

SPECIFICATIONS .................................................................................. 2

STRUCTURE AND OPERATION ........................................................... 2

INSPECTION AND REPAIR OF FRAMES ............................................. 2

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41-1
SPECIFICATIONS/STRUCTURE AND OPERATION/INSPECTION AND REPAIR OF FRAMES

SPECIFICATIONS
Item Specifications
Frame type Ladder type
Cross section configuration of side rail shape channel section

STRUCTURE AND OPERATION

1 Side rail
2 Transmission mounting cross member
< Automatic transmission >
3 Cross member
3
4 Front engine mounting support
2 5 Front engine mounting support
bracket
6 Shock absorber bracket

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1

5
4
11223

INSPECTION AND REPAIR OF FRAMES

: Bolt (M10×1.25)
: Bolt (M12×1.25)
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11224

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Ê Tightening torque Unit : N·m {lbf.ft, kg·m}
Location Parts to be tightened Tightening torque Remarks
— Bolt ( area bolt : M10×1.25) 60 to 80 {43 to 58, 6 to 8} —
— Bolt ( area bolt : M12×1.25) 98 to 120 {72 to 87, 10 to 12} —

◆ Service procedure
● Cleaning of frame
Carefully remove mud, grease, rust, etc. that is stuck to the outer and
inner surfaces of the frame.

● Inspection for frame deformation

If any fault such as deformation is found, repair the frame.

● Inspection for cracks in frame

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• Remove paint from any areas that are seemingly faulty and carefully
inspect.
• If visual inspection is difficult, inspect using color contrast penetrant
examination or other methods.
If a crack is found, repair as follows.

● Repair of crack in frame

• With the vehicle unloaded, level the frame.
• Drill a hole, about twice the thickness of the frame, 10 mm {0.39 in.}
from the end of the crack.
NOTE
If a crack is found inside the frame, drill holes at both ends of the
crack.

00238

• If the edges of the crack are not flush, make them flush with each
other.

00240

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INSPECTION AND REPAIR OF FRAMES
• Using a grinder, etc., grind a 90° V-section channel, two-thirds of the
frame thickness, then weld.
WARNING–
You must cover any inflammable materials, such as pipelines,
wiring harnesses, rubber parts, and the fuel tank, that are near
the welding site.

CAUTION–
00241 • Do not use gas welding because the high temperature produced
alters the material properties and weakens the welded area. Be
sure, therefore, to use electric welding.
• Be sure to remove the negative terminal of the battery, then
Approximately 2/3 of
frame thickness ground the welder near the area to be welded to prevent reversed
flow of current from the welder which might burn out electrical
Approxi-
components.
mately • Be sure to protect mountings such as main sills that can be
90°
damaged by heat, by using heat insulators, etc.

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NOTE
00242
• Use low-hydrogen type coated CO2 and arc welding electrodes
for welding to prevent harmful defects such as undercutting,
blow holes, etc.
• Preheat the area to be welded to approximately 50 to 350°C {122
to 662°F} before welding when the workshop temperature is
below 0°C {32°F}.

• Next, grind a V-section channel, as described above, on the opposite

side of the weld and weld. At the same time, fill the holes at both ends
of the crack by welding.

NOTE
In cold districts, heat the welded area to approximately 200°C
{392°F} after welding.

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B • After welding, grind bead A at right angles B to remove shaded area
C as illustrated and grind the area flat.
A • Finish the surface so that the frame thickness is identical to the
original thickness.

A C

B
00243

[Repairing cracks caused by rivets or bolt holes]

• To make the edges of the holes flush at the cracked area, temporarily
D
tighten bolt D in the hole.
E • Weld cracked point E at least 20 mm {0.79 in.} from the center of the
bolt.
F For welding method refer to the above-mentioned procedures for
repairing cracks. Õ P41-3.

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• After removing the bolt and making the edges flush, weld remaining
area F and fill the hole.
00244 • After drilling a hole in the filled area, install a rivet or bolt.

[Repairing using reinforcement plate]

G • To prevent concentrated stress being produced at ends G of the
G reinforcement plate, weld the plate with angle H at both ends opened
30° or less.
Do not weld area J.
H
• The reinforcement plate must have enough strength for the cracked
area.
NOTE
J : 20 mm {0.79 in.} J : 20 mm {0.79 in.} • Thickness of reinforcement plate : same as frame thickness
00245 • Reinforcement plate material : SAPH440 (hot-rolled sheet steel
for automobiles), SS400 (sheet steel for general construction), or
equivalent strength.

• After welding, heat the shaded area to 600 to 700°C {1112 to 1292°F}.
50 mm CAUTION–
{1.97 in.}
Be sure to protect mountings such as main sills that can be
damaged by heat, by using heat insulators, etc.

00246

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INSPECTION AND REPAIR OF FRAMES
● Inspection for loose rivets
• Gently tap the rivet head using an inspection hammer and judge the
condition by checking the vibration using the tip of your finger, or by
listening to the sound.
• Rust between rivet and frame indicates that the rivet is loose.
CAUTION–
Be sure to replace loose rivets because they can break or cause
cracking of the frame in the area around the rivet hole, causing
accidents.
00247

● Repair of rivet
• When removing rivets, use a center punch to make an indent in the
center of the rivet head; then, drill out using drill A or grind.
B : Incorrect
A C : Correct
CAUTION–

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Make sure that you do not damage the rivet hole.
B C

00248

• When rivetting, first clamp both plates tightly near the rivet hole using
a clamp to eliminate gaps between plates.

• Using a rivetting machine, insert the rivet (cold rivet).

• If rivetting is impossible, ream the rivet hole, drive in a reamer bolt,
fully tightening the nut, then weld it in place.
A flange bolt and flange nut should be used for the reamer bolt and
nut.

00249

● Inspection for loose bolts and nuts

• Inspect the mounting bolts in all areas for looseness. Loosened bolts
should be tightened at specified torque. Õ P41-2

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