Welding Precautions

The proper equipment and settings must be used when welding mild or high strength steel. Metal inert gas (MIG) and resistance spot welding are the preferred methods. Surfaces must be clean and free of foreign materials.

• The correct protective clothing should always be worn.
• Adequate ventilation must be provided to avoid accumulation of poisonous gases.
• A test weld should always be carried out on a test sample.
• Follow equipment manufacturer's prescribed procedures and equipment settings for the type of weld being used.
• Disconnect the battery ground cable from the battery. Refer to BATTERY, MOUNTING AND CABLES article.
• On Hybrid vehicles, depower the high voltage traction battery system. Refer to HIGH VOLTAGE TRACTION BATTERY article.
• Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
• Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted surfaces or E-coat, or when bare metal repairs are carried out. Refer to Restoring Corrosion Protection Following Repair in this article.

Underbody misalignment can affect front and rear wheel alignment, the operation of the suspension parts and drivetrain operation. Window glass cracks, door and window opening concerns, and air or water leaks at the doors are often caused by improperly tightened bolts and body misalignment.