3. INSPECT FRAME BOLTS FOR PROPER INSTALLATION TORQUE
Inspect and tighten all front end components which bolt to the frame to confirm that they are at the proper torque (refer to the Repair Procedure section of this article for proper torque requirements). This includes, but is not limited to:
> radius arm bracket bolts
> axle pivot bracket bolts
> transmission crossmember bolts
> spring tower bolts
4. INSPECT THE FRAME RIVETS
> Inspect all riveted frame and suspension components in the general area of the noise for loose or improperly seated rivets.
NOTE:
TAP THE RIVETS WITH A SMALL HAMMER. WHEN A RIVET IS NOT INSTALLED PROPERLY IT WILL MAKE A DIFFERENT SOUND THAN A "SNUG" RIVET.
> Service identified rivets according to the procedure listed in the Repair Procedure section.
5. TEST DRIVE THE VEHICLE
Road test the vehicle again to duplicate the concern. If the noise is still present, proceed to the next Step.
6. TEST JOINTS TO LOCATE NOISE
> Use a small pry bar as a "wedge" between components suspected of causing the noise. By pounding the wedge into a joint or behind a bracket, the noise should change or be eliminated if the noise is coming from that location.
NOTE:
USING A STETHOSCOPE, OR CHASSIS EARS, WILL HELP TO IDENTIFY ANY NOISE CHANGE.
> If the source of the noise is identified, proceed to the Repair Procedure section.
> If the source of the noise has not been identified by this Step, investigate other non-frame or suspension sources and/or proceed to the next Step.
7. SERVICE THE VEHICLE
a. If the noise has been identified, proceed to the specific component section in the Repair Procedure.
b. If the noise source has not been identified, refer to Figure 9 for general noise locations, operating conditions and number of occurrences. Proceed with repairing the identified components.
REPAIR PROCEDURE - (A) THROUGH (H)
(A) "Huck Fastener" - Lower Left Front #1 Crossmember Rivet Replacement
This procedure should be done on flat ground or on a drive-on lift, with the wheels pointed straight and full weight resting on the wheels. This fastener could be either a standard cold head rivet in light duty applications or a large "huck" bolt which has the appearance of a large "pop" rivet.
NOTE:
USE WARRANTY DEALER CODING: 5020, AS BASIC PART NO.
1. Remove damaged or loose rivet:
COLD HEAD RIVETS:
> Drill a 3.175mm (1/8") hole through the rivet.
> Redrill the same hole through the shank of the rivet with a 9.525mm (3/8") drill.
> Remove the rivet head with an air chisel.
> Drive out the rivet with a punch and hammer.
"HUCK" RIVETS:
> Use a flat chisel and hammer (or air chisel) to split the exposed collar of the huck fastener (Figure 1).
Click "Next" beside the image above to continue.
See also:
http://www.nloc.net/vbforum/gen-1-lightnings/209927-frame-off-resto-225k-mile-lighting-2.html#post1958385
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