I just bought a 92 W250 4x4 with what I consider slight frame damage. I took the truck to a shop to have the frame pulled and they agreed that the frame was not beyond repair. Upon further inspection they changed their story. There is a crack in the frame that originates from one of the bolt mounting holes up and over the top of the frame. It is my understanding that this is a common problem in this beast. What is the easyiest and most cost effective way to repair the crack so I can have the frame pulled. Thanks Jethrro

 

Sounds like the same thing that's on mine. I'm just going to weld the crack together. Got to find some time.

 

make a grove with a grinder along the crack and weld it up. cut a piece of steel to put behind it and weld that in too. Then just redrill any holes you covered up. I've done this to 3 trucks so far. 2 were gassers and are friends' mud trucks that are far from baby'd never had any problem with that since.

 

Known problem with the 1st gens. I would pull the radiator, intercooler, left spring arch and steering gear box so you have plenty of room to work on it. Once the spring arch has been removed, it is much easier to place the frame back in it's normal position by jacking it up or whatever. Then like mentioned, grind down the crack a little to create a good welding spot. Then just weld it up. I would also weld in some angle iron along the frame rail to make sure it doesn't happen again.

Oh, welcome aboard Jethrro. Enjoy the site as plenty of people here to help everyone out.

 

whatabout boxing the frame and putting sleeves between the two sides? Common procedure on offroading rigs.

 

Is this issue just with 4X4's, or all frames? Tanks mucho.

 

I'm sure boxing would be the best. Not sure if just 4x4 or all frames. Just a lot of stress in the area. Most cracks happen underneath the steering box mount so you don't notice it until you take it off. Either that or the front bolt that holds the mount onto the frame.

 

I don't think that boxing is the way to go -- you end up with too much web and not enough flange. The flange is what needs to be reinforced. I haven't noticed anyone mention a two wheel drive truck having this problem. I think it is all about where the steering gear mounts, combined with the huge stress riser (the crease) that stamping has there.