Freightliner stepping away from cracked frame rail.

This is not going to be that bad for you IF you take it to the right place to repair. You're talking about some out of position welding, you're going to want a better than average welder to perform, also someone who understands the flexing and movement required by truck frames so they don't put in a gusset or box it just to wind up cracking beside the gusset. I know a guy in Eureka, IL that could knock this out for you, ace welder, private shop, lot's of experience with trucks. Also TAFA in Nashville, TN would be good, they're recommended on here frequently for alignments, but they do a lot of frame straightening and repair.

 

What the history is really doesn't matter. Nothing is going to change the fact that it's cracked now, and that totally sucks great big slimey green donkey dongs. The only ray of sunshine is that a talented welder should be able to fix that fairly easily at a cost much lower than say, an in-frame, for example.

Somewhere on this forum is a thread discussing a company that does frame rail replacement at a really good price. Back in the 1980's KW had a recall on frame rails & a friend of mine had his replaced. As I recall he said it took 2 mechanics a day to change a rail, they just blocked everything up, took out all the bolts, slid the old rail out & the new one in. All your effing huck bolts might complicate that a bit..........

As someone who bought my truck about the same time you bought yours & is suffering my own travails, you have my empathy.

 

Welding alone will not be a legal repair, nor trustworthy. It will need to be sleeved, or gloved, to give it strength. Freightliner can order you a new rail, by VIN. They ship them through Laredo everyday.
BTW, out of warranty is out of warranty, regardless if it 6 months, or one day.

 

If you look where its circled, thats the frame rail width getting wider not a bend.
Why take the motor out to weld the frame?
If you find a shop who builds race car frames/ cages, I'm going to guess they can fix that no problem. Put another piece of C channel inside and weld away. I dont see this being all that bad MN. Good luck with the fix.

 

Good deal. I'm guessing a cost of maybe 3-400 for labor is about right?

 

How will they heat treat the flanges after welding? The temper will be lost in the areas of the flanges that were welded.

 

There is a reason they stretch the frame in the rear and not the front

 

MN sounds like you are in good hands . You both will be fine.