C. Install Steering Gear Crossmember Reinforcement Bracket

NOTE:
Steering gear crossmember reinforcement repair requires the use of P/N CAAM9981 repair package.

NOTE:
For vehicles that have had a new steering gear crossmember installed (Section "B"), proceed to step 5.

1. Remove both rear tire and wheel assemblies.

2. Remove the fasteners that attach the battery access panel (Figure 2) and remove the panel.

3. Disconnect and isolate the negative battery cable at the battery.

NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.

4. Disconnect and isolate the positive battery cable at the battery.

CAUTION:
Failure to isolate both the positive and negative battery cables from the battery may cause Powertrain Control Module PCM) and/or battery damage during welding.





5. Place the steering gear reinforcement bracket into position, just in front of the steering gear crossmember and on top of the frame rails (Figure 9). The reinforcement bracket must be centered between the frame rails.

NOTE:
The reinforcement bracket must be positioned flush against the steering gear crossmember. Minor grinding of the existing steering gear crossmember welds may be required.

6. Mark all of the locations on the steering gear crossmember, frame rails and reinforcement bracket where welding will be performed with a grease pencil (Figure 9).

7. Remove the reinforcement bracket from the vehicle.

8. Using a grinding wheel, remove all E-coat from the reinforcement bracket, steering gear crossmember and frame rails within 1 inch of the weld areas marked in Step 6.

9. Place the reinforcement bracket back into position and clamp it into place.

10. Tack weld each side of the reinforcement bracket to the frame rail (Figure 9).

WARNING:
Only use the specified welding wire (Lincoln Electric Co. NR-211 MP). Do not substitute with other types or thickness welding wire.

IMPORTANT:
All welding must be performed by a qualified welder.

NOTE:
Refer to the Welding Procedure Specifications Chart in this document for all welder set-up information.

CAUTION:
Attach the welder ground lead directly to the frame as close to the weld area as possible.

11. Remove the clamps and verify that the reinforcement bracket is properly positioned. Adjust the reinforcement bracket position if necessary.

12. Weld the reinforcement bracket to the frame rails and steering gear crossmember as shown in Figure 9.

NOTE:
Vehicles that have had a new steering gear crossmember installed must have an extra weld applied as shown in Figure 9.

13. Clean all weld areas and apply zinc rich primer (P/N CAAM9987) to all new welds and bare metal.

14. Afier the zinc rich primer is dry, apply black spray paint (P/N CAAM9988) to cover the zinc rich primer applied in Step 13.

15. Continue with Section "D - Install Frame Gussets."