General Procedures — Welding Precautions

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NOTICE: SRS components must always be de-energized and disconnected before starting any welding procedure.

NOTICE: Electronic modules and related wiring may be damaged when exposed to heat from welding work. Carefully disconnect and remove them or relocate them away from areas exposed to heat.

1. 1
   A test weld must always be performed on a test sample.
2. 2
   Always wear proper protective clothing.
3. 3
   Always work in a well-ventilated area to avoid accumulation of harmful gases and gases that displace oxygen.
4. 4
   Place protective covers around components and wiring harnesses to protect them from weld spatter.
5. 5
   Use grinding wheels and wire brushes suitable for the type of material being welded.
6. 6
   Follow the equipment manufacturer's instructions and equipment settings for the type of welding used. ER70S-3 or ER70S-6 wire is commonly used for MAG welding of steel.
7. 7
   Disconnect and insulate the battery ground cable.
8. 8
   Components made of boron, martensitic, high-speed steel (high-strength steel) and UHSS (ultra-high-strength steel) must not be heated for straightening or repair. Severely bent or twisted components must be replaced with new ones.
9. 9
   Factory welds may be replaced with STRW (resistance spot welding) spot welds or MAG plug welds.
10. 10
    MAG welds must match the factory welds in both location and quantity.
11. 11
    Holes for MAG plug welds must be 8 mm (0.31 in) in diameter.
12. 12
    The number of resistance spot welds must equal the number of factory welds and be located next to the original weld location.
13. 13
    Disconnect onboard modules and protect them from possible heat damage and electric shock during welding.
14. 14
    Where applicable, use weld-through primer.
15. 15
    When welding, always position the ground clamp as close as possible to the weld area.
16. 16
    Never connect the welder ground clamp to the vehicle subframe.
17. 17
    Never weld the vehicle subframe, steering or suspension components. Service by replacement only.