Any Welders Out There???

[ford4x4fun]

Ok for those of you that are welders! Me I am not! Anyhow the guys that did my clutch also murdered my crossmember. This is basically what the did.

1. Couldn't get the bolts out, punched them out with a torch.
2. Cut the crossmember just to the drivers side of the transmission to pull out the Tranny.
3. When they put the crossmember back in, they didn't replace the bolts, just tack welded the bolt holes (IDIOTS)
4. Than welded the crossmember back together, with no other support.
5. They also cut my custom exaust off, and when they welded them back up they didn't do a good job now I have exhuast leaks.

Anyhow, what can I do to fix my crossmember, it isn't like those things are just laying around. I worry about the strain, the truck is going to be a 4x4 again, once I get my transmission and transfer case rebuilt, which those guys also jacked up. But I don't want to have to worry about that breaking while out on a trail. I am not a welder and don't know the first thing about welding for reinforcement purposes. Anyhow Thanks for looking.l

[AlleyCat]

A couple suggestions.

1) Stay away from the butcher that changed the clutch.
2) Remove the crossmember and take it to someone who knows fabrication work.They will be able to suggest a good way to reinforce it.
3) Reinstall the crossmember with grade 8 bolts.Grade 5 will work but 8 is stronger.
4) Go back to the exhaust shop and see if they can weld the leaks shut.

Did I mention you should stay away from the butcher who changed the clutch?

[ford4x4fun]

Thanks,

Oh yeah staying away from the butcher shop! Grade 8 bolts will be used. I will remove it I guess when I am on leave. And send it to the fab shop. I was shocked at the mess they made for me. Did I mention my truck went in 4wd and came out 2wd with my transmission and transfer case in parts?

Thanks for the advice!!!

[AlleyCat]

I misread the part about the trans and t-case. Your truck most likely has an NP435 trans with a single speed ( no low range) transfer case.To me that setup is about as complicated as a glass of milk.Of course if they were dumb enough to cut the crossmember in half then a glass of milk may be beyond their comprehension.

[Kurt Combs]

I am beyond dumbfounded, who are these idiots? Cutting the nuts off of a bolt is acceptable and good use of a torch, beyond that they were just completely out of the range of acceptable practice, other than removing an engine in a wrecking yard. The problem with the welded cross-member is the heat affected zone, the area at the edge of the weld, which is where it will crack, not to mention a ridged spot where the weld is that will flex at a different rate than the rest of the cross-member creating a crack at the weld. You just don't do that to a structural member without some plan to compensate for the damage. Welding the cross-member back in it way beyond acceptable, and the exhaust, wow. I am pretty easy going on complaining and usually just take my business else where, but in this case I would sue them in small claims court for the cost of returning the truck to it original state when taken to their shop. Oh, by the way, I was a fabrication welder for years and passed the AWS certified welding 1inspection exam, so I have some knowledge in this area. They are idiots!!! Did they charge you flat-rate for this job?

[ToughOldFord]

I am beyond dumbfounded, who are these idiots? Cutting the nuts off of a bolt is acceptable and good use of a torch, beyond that they were just completely out of the range of acceptable practice, other than removing an engine in a wrecking yard. The problem with the welded cross-member is the heat affected zone, the area at the edge of the weld, which is where it will crack, not to mention a ridged spot where the weld is that will flex at a different rate than the rest of the cross-member creating a crack at the weld. You just don't do that to a structural member without some plan to compensate for the damage. Welding the cross-member back in it way beyond acceptable, and the exhaust, wow. I am pretty easy going on complaining and usually just take my business else where, but in this case I would sue them in small claims court for the cost of returning the truck to it original state when taken to their shop. Oh, by the way, I was a fabrication welder for years and passed the AWS certified welding 1inspection exam, so I have some knowledge in this area. They are idiots!!! Did they charge you flat-rate for this job?

I agree. And I'm not found of sue-happy people, but it's justified in this case. I'd report them to the BBB as well.

[MadMaxetc]

I am beyond dumbfounded, who are these idiots? Cutting the nuts off of a bolt is acceptable and good use of a torch, beyond that they were just completely out of the range of acceptable practice, other than removing an engine in a wrecking yard. The problem with the welded cross-member is the heat affected zone, the area at the edge of the weld, which is where it will crack, not to mention a ridged spot where the weld is that will flex at a different rate than the rest of the cross-member creating a crack at the weld. You just don't do that to a structural member without some plan to compensate for the damage. Welding the cross-member back in it way beyond acceptable, and the exhaust, wow. I am pretty easy going on complaining and usually just take my business else where, but in this case I would sue them in small claims court for the cost of returning the truck to it original state when taken to their shop. Oh, by the way, I was a fabrication welder for years and passed the AWS certified welding 1inspection exam, so I have some knowledge in this area. They are idiots!!! Did they charge you flat-rate for this job?

I agree. And I'm not found of sue-happy people, but it's justified in this case. I'd report them to the BBB as well.

[Doug Comer]

Its been awhile for me, I can't remember but don't those crossmembers bolt in? If so I might have one if your interested, Doug