Universal Medium Axle Truss Instruction Manual

1. Product Overview

The Barnes 4WD Universal Axle Truss is engineered to provide a robust attachment point for link suspension systems on various axle types. Constructed from a single piece of 1/4-inch steel, it is CNC laser cut and bent in-house using American steel. This one-piece design simplifies installation, requiring only placement on your axle at the desired pinion angle and subsequent welding. This manual provides essential information for safe and effective installation and use.

Figure 1: Barnes 4WD Universal Medium Axle Truss. This image displays the complete truss unit, showcasing its one-piece design and robust construction.

2. Safety Information

Always prioritize safety when working with automotive components and welding equipment. Failure to follow safety guidelines can result in serious injury or property damage.

• Wear appropriate Personal Protective Equipment (PPE), including safety glasses, welding helmet, gloves, and protective clothing.
• Ensure adequate ventilation when welding to prevent inhalation of fumes.
• Disconnect the vehicle's battery before performing any welding to prevent damage to electrical systems.
• Secure the vehicle properly on jack stands or a lift before working underneath it.
• Allow welded components to cool completely before handling.
• Keep a fire extinguisher readily available during welding operations.
• If you are not experienced with welding or automotive fabrication, seek assistance from a qualified professional.

3. Installation Instructions

The Universal Axle Truss is designed for straightforward installation, primarily involving welding to your existing axle. Professional installation is recommended for optimal results and safety.

Required Tools and Materials:

• Welding equipment (MIG, TIG, or Stick welder)
• Grinder with appropriate discs
• Measuring tape and marking tools
• Clamps
• Safety glasses, welding helmet, gloves

Installation Steps:

1. Prepare the Axle: Clean the surface of your axle thoroughly where the truss will be mounted. Remove any rust, paint, or debris to ensure a strong weld. The truss ships bare and may require some grinding depending on the application.
2. Position the Truss: Carefully place the Universal Axle Truss onto your axle. Determine the desired pinion angle and the optimal position for your specific suspension setup. The one-piece design simplifies this step.
3. Secure the Truss: Use clamps to firmly hold the truss in place on the axle. Double-check its alignment and angle before proceeding to welding.
4. Weld the Truss: Begin welding the truss to the axle. Apply strong, consistent welds along all contact points. Ensure full penetration for maximum strength. Allow for proper cooling between passes if necessary to prevent warping.
5. Inspect Welds: After welding is complete and the assembly has cooled, thoroughly inspect all welds for any defects, cracks, or insufficient penetration. Re-weld any areas that appear weak.
6. Finish: Once satisfied with the welds, you may choose to paint or coat the truss and welded areas to prevent corrosion.

Figure 2: Dimensional Drawing of Universal Medium Axle Truss. This diagram provides key measurements for the truss, including length, height, and width, to aid in fitment and installation planning.

4. Maintenance

Once installed, the Barnes 4WD Universal Axle Truss requires minimal maintenance. Regular inspection is recommended to ensure its continued integrity.

• Visual Inspection: Periodically inspect the truss and its welds for any signs of rust, cracks, or damage, especially after off-road use.
• Corrosion Protection: If the truss was not painted or coated after installation, consider applying a protective finish to prevent rust, particularly in corrosive environments.
• Cleanliness: Keep the truss free from excessive dirt, mud, and debris, which can trap moisture and accelerate corrosion.

5. Troubleshooting

Most issues related to the axle truss will stem from improper installation. Adhering strictly to the installation instructions will prevent common problems.

• Weld Cracks: If cracks appear in the welds, this indicates insufficient penetration, improper welding technique, or excessive stress. Consult a professional welder for repair.
• Misalignment: If the truss appears misaligned after installation, it may affect suspension geometry. This typically requires cutting the welds, realigning, and re-welding.
• Corrosion: Rust on the truss indicates a lack of proper protective coating. Clean the affected area and apply a suitable rust-inhibiting paint or coating.

6. Specifications

7. Warranty and Support

For specific warranty information or technical support regarding your Universal Medium Axle Truss, please contact Barnes 4WD directly. Details regarding product warranties are typically provided at the point of purchase or on the manufacturer's official website.

It is recommended to retain your proof of purchase for any warranty claims.