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For all guys with a trimmed engine crossmember

Burns

Elite Explorer
Moderator Emeritus
Joined
October 20, 2004
Messages
8,877
Reaction score
38
City, State
Pulaski, TN
Year, Model & Trim Level
1991 Explorer/2002 F-250
When I did my SAS I trimmed the engine crossmember just to make sure the diff was not going to hit it.

Then end result after almost 3yrs is a cracked front crossmember.

crack.jpg


Its in the process of getting welded back together but this is just a reminder to check stuff like this.
 



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whats that from ? looks like you got a substancial leak going on there on the right hand side .
 






im sorry I cant see the crack, where are we talking exactly? LOL

Plate that sucker from behind the FULL WIDTH of the x member

After you trimmed it, did it need it?
 






That why I just cut mine out completly! :p:
 






It does not get close. We thought it did and went ahead.

I want to pull it out and build another crossmember but that takes more time than i have right now.

Its been welded back and front. I may plate it soon over the crack.
 






whats that from ? looks like you got a substancial leak going on there on the right hand side .

I know its getting worse and worse. Valve cover gasket and i think i may have another leak up there. Gonna tear into that someday
 






if you plate the crack a new crack will appear on the side of the plate, its murphy's law

I would plate it from in front or from the back the full length or gusset it for strength like Rock Ranger did
 






Ok ill give his a search tonight and check it out. Thanks
 






That is a case of a stress riser -- I would have smoothed out the cut in the beginning and maybe filled in that hole.

But why not just make a new cross member like the one Section525 made? Its fairly easy and would be a lot stronger than the stock.
 






Thats my plan. We didnt have the time when i did that so it survived. Its been welded up crack and hold and im gonna try to get it smoothed out tomm.
 












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