SFN-20260331A Transverse Track Rod Bracket Field Update

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TICO Document #: TES-297

Description of Procedure: Replace welded track rod bracket with a bolt-on replacement bracket

Units Affected: All Units prior to 2026

Parts Required: 970153 - Service repair kit

Planned Labor: 6.00

Recommended Tools:

  • Magnetic Drill with 3/4” drill bit

  • angle grinder

  • plasma cutter

Instructions:

  1. Park vehicle on flat surface, apply parking brake, and chock wheels. Proceed with the “Lock Out, Tag Out” policy.

  1. Secure the suspension with jack stands.

  1. Being very careful not to cut into the frame material airline and harness must be moved upwards to prevent damage. Remove old bracket by cutting any welds to the inside frame wall with an angle grinder or plasma cutter.

  • The bracket may need to be removed in pieces.

  • Clean up the Edges of the hole with a grinder to remove any excess weld material.

  • Carefully remove any weld splatter on the inside of the rail wall to make a flat mounting surface for the new bracket.

  • Avoid damaging the galvanized finish or the rail base material as much as possible. Paint any exposed surfaces before inserting the new bracket.

It has been noted that some brackets were welded both inside and outside the frame, as they should, for proper strength. Others were only welded to the outer frame.

  1. If the bracket being removed is welded inside the frame, only remove as much of the bracket as possible using a plasma cutter.

  • Grind the remaining bracket and weld material to within .375” height from the outside frame wall.

  • Avoid damaging the outer wall.

  • The new bracket should fit inside the old bracket remnants.

  • Remove any splatter or stray weld material that will inhibit a flush fit for the new bracket.

  • Paint any newly exposed surfaces to prevent corrosion

  1. Use the drilling template in the repair kit drilling to ensure the holes are properly placed and sized.

  • Clean up any weld splatter on the outside of the rail without damaging the finish as much as possible.

  • If the vertical dimensions are not possible due to an irregular weld bead, place the plate as close to the weld bead as possible.

  • Make certain the holes are centered on the opening inside of the frame.

  1. Use the drilling template to mark the four holes.

  • Make certain the pattern is centered on the opening on the inside of the rail.

  • Use a Magnetic Drill to drill the 3/4” holes in the frame rail.

  1. Insert bracket into the hole in frame as shown below.

  • Line up the holes drilled in the frame.

  • Verify a good flush mounting on the frame wall.

  1. Attach bracket and backer plate to the frame using:

    (4) 3”x5/8” - 11 grade 8 hex bolts

    (8) 5/8” flat grade 8 zinc plated washers

    (4) 5/8” -11 grade 8 nylock nut

  • Insert the top row of bolts first.

  • Use a crows foot wrench as a back-up wrench and torque top row.

  • Then, insert and torque bottom row.

  • Torque from the nut side to 125 ft-lbs

  1. Reassemble the track rod and casting as before using new hardware:

    (2) 5-1/4” x 5/8” -11 grade 8 hex bolts

    (4) 5/8” grade 8 zinc plated flat washers

    (2) 5/8” -11 grade 8 nylock nuts

  • Torque from the bolt head side to 125 ft-lbs

  1. Remove “Lock Out, Tag Out” plaque.

  1. Return vehicle to service.