I. Differential Bracket Repair (Cracks More Than 3/8 In.)
NOTE:Differential bracket repair requires the use of P/N CAAP9984 repair package.
1. Remove the battery from the battery tray and store it a safe distance from the welding area.
2. Disconnect and remove the left half shaft from the wheel flange.
3. Remove the original differential bracket from side of frame rail using a cut off wheel to remove existing welds (Figure 15).
CAUTION:
Do not use plasma arc cutting equipment or a cutting torch to remove the original differential bracket.
4. Drill a 1/8" inch (3 mm) hole at the end of each crack in the frame.
5. Grind the frame surface flush.
CAUTION:
The repair plate must overlap the damaged frame rail by a minimum of 3/4 inch (19 mm). If a larger plate is needed use .080" thick cold rolled steel.
CAUTION:
The reinforcement plate must be flush against the side wall of the frame rail before welding.
6. Use a grinding wheel to clean any paint and/or corrosion from where the reinforcement plate will meet the frame.
7. Clamp the reinforcement plate into position (Figure 26). The reinforcement plate must be flush against the frame before welding.
8. Tack weld the reinforcement plate into position as shown in Figure 26.
9. Remove the clamps used to hold the reinforcement plate to the frame rail.
10. Weld all of the outside edges of the reinforcement plate to the frame rail using flux core arc welding method.
11. Measure forward from the rear frame brace 2-5/8 inches (67 mm) and then scribe a line as shown in Figure 27.
12. Find the center point of the new differential bracket and then scribe a line as shown in Figure 28.
13. Position the new differential bracket on the frame rail. Align the scribe line made on the reinforcement plate with the line made on the differential frame bracket to obtain the correct right-to-left location (Figure 29). The top tab of the differential frame bracket must be tight against the top of the frame rail. Clamp the bracket into position.
14. Tack weld the differential bracket into position (Figure 29). Recheck the bracket location and adjust if necessary.
15. Weld all sides of the new differential bracket to the reinforcement plate (top, bottom, front, and sides). Weld the top tab of the bracket to the top of the frame rail.
16. Apply a weld where the backside of the differential bracket meets the bottom of the frame rail (Figure 30).
17. Install the gusset bracket (Figure 31) to the underside of the frame rail and position the gusset against the back of the differential mounting bracket. Weld all areas where the gusset bracket meets the frame rail and differential bracket.
NOTE:
The lower rear side of the gusset bracket, when installation the correct position, will not be in contact with the frame or differential bracket.
18. Straighten (if necessary) the toe link bracket and weld it to the side of the differential bracket (Figure 29). If the toe link is severely damaged continue with Section "J. - Replace Rear Toe Link Bracket."
19. Clean all weld areas and apply zinc rich primer to all new welds and bare metal.
20. After the zinc rich primer is dry, apply black spray paint to cover the zinc rich primer applied in Step 19.
21. Continue with Section "K - Install Fuel Tank - Roadster" or Section "L - Install Fuel Tank - Coupe"