Xj frame crack welding help ...!

rockclimber said:

you're going to need to figure out the settings on the welder yourself. every welder is different. or take it to a shop

the steps for repairing the crack are:
sand the paint off around the crack
drill a 1/8" hole at each end of the crack
weld the crack
sand the weld smooth
you could also
put a peice of 1/8" or 3/16" plate over the crack area and rosette weld (plug weld) it to prevent more cracking

where is the crack?

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highspeed said:

Yikes. thats a tough spot. Need to remove everything around the crack thats bolted in, so you can see the full crack. Do the steps he said above and add plating to strengthen that spot.

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adiga101 said:

what kind of welding should i use ?? wire size ? sittings on ther welder ?? anyone know what cause this ? i don't go offroading but the only problem i have it in the past i was in the high way suddenly the steering wasn't response i stopped and check what happend i saw only one bolt hold the steering box is that cause it ??

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highspeed said:

You need to make sure all the bolts are tight; use thread locker and/or lock washers. Fix the weld area first. You need a good penetrating welder, probably over 150 amps. Wire size depends on a few things. I personally own a wire feed and stick welder. I would use my stick welder on you problem, because it's hotter and I am more comfortable with it.

Sounds like you need to take it to someone.

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highspeed said:

You need to make sure all the bolts are tight; use thread locker and/or lock washers. Fix the weld area first. You need a good penetrating welder, probably over 150 amps. Wire size depends on a few things. I personally own a wire feed and stick welder. I would use my stick welder on you problem, because it's hotter and I am more comfortable with it.

Sounds like you need to take it to someone.

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xcm said:

take a cutoff wheel and cut into the crack slightly, so your weld has somewhere to go, and doesnt just 'sit on top' like the first<?> repair, then mig it with the appropriate settings.

It WILL crack again if you dont add a reinforcement plate.

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rockclimber said:

Wire size and settings will be determined by the welder.

I use .o30 wire for almost everything

My welder is only 115v so I crank it up as high as it will go with a slow wire speed to get the most out of it

You need to grind that area down with a flap disc on an angle grinder until it is nice and smooth and flat.

XCMs suggestion is a good one

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jeeperjohn said:

The kit is a good one but I think you need some custom repair work on that if you want it to be reliable. It needs a doubler on the bottom and both sides of the frame in the area of the gearbox.

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