Welding Precautions
WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
When welding is performed anywhere on the vehicle, precautionary measures should be taken to prevent damage to electrical system wiring or components. Welding cables should never be allowed to lay on, near or across any electrical wiring or electronic component during welding.
CAUTION:
When welding low carbon steel side rails (35,000 psi yield strength), emphasis should be placed upon weld application techniques to avoid stress risers that may adversely affect frame operating stresses. When welding within 4 inches of any crossmember rivet, remove the rivets and replace with grade 8 bolt/nuts.
- If welding must be done on a frame, make sure the following requirements are met:
- Disconnect the battery(s). For additional information, refer to BATTERY, MOUNTING AND CABLES .
- Disconnect the instrument cluster module (ICM), powertrain control module (PCM)/engine control module (ECM), fuel pump driver module (gas only), anti-lock brake system (ABS) module, 6.0L diesel fuel injection control module (FICM) and the body security module (BSM).
- Do not use gas welding equipment; mig or arc welding are the only approved methods.
- Replace spot-welded components by spot welding where possible.
- If spot welding is not possible, use puddle welding.
- Where the frame wax coating and the bracket E-coat have been removed, apply anti-corrosion coating to all affected surfaces of the frame, bracket and weld areas.
- Clean the welded areas with a wire brush.
- Use a wax and grease remover for a final cleaning of the weld areas.
NOTE:
Do not weld on any reinforcement. Use compression type fasteners when attaching any component to the frame in the reinforcement area.