Help! Welded cross support 4 NP205

[rickstores69chev]

I just started unbolting my 203 setup to remove it and install my new np205/th350 combo I purchased. I can tell the truck must have had a 205 previously because you can see the old bolt pattern that is maybe a few inches forward & there is still a bolt in one of the old holes. Big problem though. I could not believe I did not see this when I bought the truck. The crossmember is bolted correctly. It is bolted on each side of the frame. However, some crazy person welded the inner supports on each side to the inner frame rail. It is a terrible weld job and now I can not move it forward as necessary. I am hoping that once I remove the bottom cross member that each of those side pieces will break off at the welds since it looks like a nasty weld. If not, I am not sure what to do. Pretty tight area to put a grinder in there. Plus fuel lines coming across. Don't want to butcher the frame all up with a torch either. The whole undercarriage is coated with oil from the old tranny. Good potential for a fire.

You guys have any ideas or comments? I finally got up the nerve to do this job. I thought I could handle it. Now this weird weld scenario. I don't think this is common mounting techniques. Perhaps it is for some. I would have just drilled a couple new holes and bolted it. Also, Would have considered if I had to remove it.

Look forward to some ideas, soutions, comments!

Rick
Gig Harbor, WA

[Americanrider]

Sawzall & a couple of fire extingishers.... since it sounds like you will not be using that crossmember again.

[rickstores69chev]

I just looked at it. Shoot. Sawzall is perfect to cut it off other than I can not mount the new brackets I would have to get. Because I need to move it about 8 inches forward to clear the old piece of metal left from cutting. I only need to come forward about 2 inches. I don't know, but maybe I do not need those upper braces. Perhaps the bottom cross member is enough. I will keep my brain turning. Do you know anywhere in Tacoma that I could take the truck to that could do the swap for me? Maybe they could get in there with a cutting torch since the truck would be in the air. Probably pull the fuel tank out.

[rjstj]

Give Cascade Off Road a call.
They're in Puyallup. If they can't do it then I'm pretty sure they know who can. LazyDaze comes to mind also but I'm not sure where they are. They build some pretty tough trucks though.

Randy

[rickstores69chev]

Thanks rjstj. I will call them in the morn. It is not much to remove the setup. But if I don't get rid of those cross members that are welded I will not be able to put my new setup in. Then I would have to tow it somewhere to torch those pieces off since I have to pull the tranny and transfer to get to the inner frame. Having looked at it again tonight, I think a reall good torch person could heat the nasty weld beads the pry it off.

[leadfoot067]

you could also try billy bobs off road..286-2344, if you used a sawzall...once the crossmember was out of the way shouldnt you be able to get in there and grind off the welded parts?

[rickstores69chev]

It is possible that I might be able to. Perhaps with a very small grind wheel. Maybe something like a dremmel. As long as i Can maneuver it between the top and bottom rail. Pretty tight area. Also just a redicioulous unexpected scenario. I am going to take a picture and post it. It will take alot of clean up or I will never get the same mounts back in place. I am likking all the thoughts. It is already looking better!

Cheers!

Rick

[rickstores69chev]

Well Here are pictures of the left side and right side. Think I will be able to save the supports? Pretty bad welding so maybe it is not as bad. What type of grinder yo think I should try?

[Blazer1970]

You should be able to snap those off there once you disassemble the crossmember.

[rjstj]

Since it doesnt' look like there are any bolts in the top of the crossmember why don't you put a jackunder it, unbolt the bottom bolts and lower the jack. The weight of the transfer case may just pop those welds. It might need a little persuasion but they look alot like some of my welding attempts and they pop right off with a hammer or chissel.

Good luck.

[Phuloi68]

From the looks of the welds try what the above posts say to do. If that doesn't work, concentrate on working on one side. If you can't use a torch to wash the welds out (if you are experienced in using a torch), try a hammer and chisel. From the sloppy welds, that may cut them pretty easy. When you get the one side free, you might be able to grab the bracket and move it up and down to break the welds on the other side.
Don't you just love going behind someone else's sloppy repairs??

[rickstores69chev]

Yes no doubt this is a mess! Whoever did this was nuts! Obviously they were not thinking of the guy who had to remove it in the future. I appreciate all the ideas. I am leaning on going for it. Removing the tranny and transfer. Then hammering, chiseling, grinding this out. I am crossing my fingers it will go smooth. I was worried of pulling everything and then having to tow the truck to a welding shop. I could see a small spot weld to hold it together when they were mounting it. But wow! Real interesting to say the least.

[454_72_4X4]

Originally Posted by rickstores69chev

Yes no doubt this is a mess! Whoever did this was nuts! Obviously they were not thinking of the guy who had to remove it in the future.

Haha, The guy that did that is probably working in Detroit as a design engineer now!

The pieces that are welded are not the actual crossmember are they? Can't remember.
If you can get the crossmember out and those pieces aren't welded on the top side also, they will come out by just bending them back and forth, (up/down). Even the best welds won't hold very good if they're not welded on both sides of a lap joint.

[rickstores69chev]

YEs it is the (2) side pieces that bolt to the crossmember and then to the top frame rail. In this case we are welded. I looked above, Thank goodness it is not welded there to. They did do it on the side. One side only. I am going to try and finish unbolting everything this weekend. Rent a transmission jack. Or perhaps someone else has a better suggestion on what to do. Not sure I will have a helper. I have lifted & wrestled transmissions by myself never with a transfer case though. That NP205 is a monster. Someone told me the 203 coming out was more heavy.

Thanks for all the feedback. It has built my confidence back up.

Rick

[leadfoot067]

i strongly recomend NOT doin it alone....i dropped a 203 on my arm a couple years ago...it doesnt feel good....if ya hafta do it alone rent a tranny jack and make sure its strapped tight.....

[rickstores69chev]

Thanks for the suggestion. I definetly will not attempt it without a tranny jack. I have also heard of using 2-3 ratchet straps in combination with the jack. Then supposedly you can ratchet it down with the straps in increments. Alternating between the tranny jack and the straps. I think it is more of a saftey catch then a raising technique. I am definetly more paranoid taking one out then putting one in. I will think it through if I end up doing it myself.

[leadfoot067]

well i was installing the 203 low range box part of the doubler in my rig when it fell on my arm.....im glad it wasnt the whole 203