Chrysler Town, Dodge Caravan. Manual — part 435
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE
FAMILY NAME
COMMON TRADE NAME
TYPICAL APPLICATION
ASA
ACRYLONITRILE STYRENE
ACRYLITE
LURAN S
CONSOLES, GRILLES
ABS
ACRYLONITRILE
BUTADIENE STYRENE
TERLURAN
9
A
9
PILLARS, CONSOLES,
GRILLES
ABS/PC
ABS/PC ALLOY
PULSE, PROLOY,
BAYBLEND
DOORS, INSTRUMENT
PANELS
ABS/PVC
ABS/PV ALLOY
PROLOY, PULSE, LUSTRAN,
CYCLOVIN
DOOR PANELS, GRILLES,
TRIM
BMC
BULK MOLDING
COMPOUND
BMC
FENDER EXTENSIONS
EMA
EHTYLENE METHYL
ACRYLATE/IONOMER
SURLYN, EMA, IONOMER
BUMPER GUARDS, PADS
METTON
METTON
METTON
GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO
MODIFIED
POLYPHENYLENE OXIDE
MPPO
SPOILER ASSEMBLY
PA
POLYAMID
ZYTEL, VYDYNE, PA,
MINLON
FENDERS, QUARTER PANELS
PET
THERMOPLASTIC
POLYESTER
RYNITE
TRIM
PBT/PPO
PBT/PPO ALLOY
GERMAX
CLADDINGS
PBTP
POLYBUTYLENE
THEREPTHALATE
PBT, PBTP, POCAN, VALOX
WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC
POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOY
BEXLOY,
9
M
9
, PBTP/EEBC
FASCIAS, ROCKER PANEL,
MOLDINGS
PC
POLYCARBONATE
LEXAN, MERLON, CALIBRE,
MAKROLON PC
TAIL LIGHT LENSES, IP TRIM,
VALANCE PANELS
PC/ABS
PC/ABS ALLOY
GERMAX, BAY BLENDS,
PULSE
DOORS, INSTRUMENT
PANELS
PPO
POLYPHENYLENE OXIDE
AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPO
INTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN SHROUD
PPO/PA
POLYPHENYLENE/
POLYAMID
PPO/PA, GTX 910
FENDERS, QUARTER PANELS
PR/FV
FIBERGLASS REINFORCED
PLASTIC
FIBERGLASS, FV, PR/FV
BODY PANELS
PS
POLYSTYRENE
LUSTREX, STYRON, PS
DOOR PANELS, DASH
PANELS
RTM
RESIN TRANSFER
MOLDING COMPOUND
RTM
BODY PANELS
SMC
SHEET MOLDED
COMPOUND
SMC
BODY PANELS
TMC
TRANSFER MOLDING
COMPOUND
TMC
GRILLES
23 - 4
BODY
RS
BODY (Continued)
CODE
FAMILY NAME
COMMON TRADE NAME
TYPICAL APPLICATION
UP
UNSATURATED
POLYESTER
(THERMOSETTING)
SMC, BMC, TMC, ZMC, IMC,
XSMC, UP
GRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC
ETHER/ESTER BLOCKED
CO-POLYMER
EEBC
BUMPERS
EEBC/PBTP
EEBC/POLYBUTYLENE
TEREPTHALATE
EEBC, PBTP, BEXLOY
BUMPER, ROCKER PANELS
EMPP
ETHYLENE MODIFIED
POLYPROPYLENE
EMPP
BUMPER COVERS
EPDM
ETHYLENE/
PROPROPYLENE DIENE
MONOMER
EPDM, NORDEL, VISTALON
BUMPERS
EPM
ETHYLENE/
PROPROPYLENE CO-
POLYMER
EPM
FENDERS
MPU
FOAM POLYURETHANE
MPU
SPOILERS
PE
POLYETHYLENE
ALATHON, DYLAN,
LUPOLEN, MARLEX
-
PP
POLYPROPYLENE
(BLENDS)
NORYL, AZDEL, MARLOX,
DYLON, PRAVEX
INNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM
PP/EPDM ALLOY
PP/EPDM
SPOILERS, GRILLES
PUR
POLYURETHANE
COLONELS, PUR, PU
FASCIAS, BUMPERS
PUR/PC
PUR/PC ALLOY
TEXIN
BUMPERS
PVC
POLYVINYL CHLORIDE
APEX, GEON, VINYLITE
BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM
REACTION INJECTED
MOLDED POLYURETHANE
RIM, BAYFLEX
FRONT FASCIAS, MODULAR
WINDOWS
RRIM
REINFORCED REACTION
INJECTED MOLDED
PUR, RRIM
FASCIAS, BODY PANELS,
BODY TRIMS
TPE
THERMO POLYETHYLENE
TPE, HYTREL, BEXLOY-V
FASCIAS, BUMPERS,
CLADDINGS
TPO
THERMOPOLYOLEFIN
POLYTROPE, RENFLEX,
SANTOPRENE, VISAFLEX,
ETA, APEX, TPO, SHIELDS,
CLADDINGS
BUMPERS, END CAPS,
TELCAR, RUBBER, STRIPS,
SIGHT, INTERIOR B POST
TPP
THERMO-
POLYPROPYLENE
TPP
BUMPERS
TPU
THERMOPOLYURETHANE,
POLYESTER
TPU, HYTREL, TEXIN,
ESTANE
BUMPERS, BODY SIDE,
MOLDINGS, FENDERS,
FASCIAS
RS
BODY
23 - 5
BODY (Continued)
PANEL SECTIONING
If it is required to section a large panel for a plas-
tic repair, it will be necessary to reinforce the panel
(Fig. 1). To bond two plastic panels together, a rein-
forcement must overlap both panels. The panels
must be “V’d” at a 20 degree angle. The area to be
reinforced should be washed, then sanded. Be sure to
wipe off any excess soap and water when finished.
Lightly sand or abrade the plastic with an abrasive
pad or sandpaper. Blow off any dust with compressed
air or wipe with a clean dry rag.
When bonding plastic panels, Follow repair mate-
rial manufacturers recommendations. Be sure that
enough adhesive has been applied to allow squeeze
out and to fill the full bond line. Once the pieces
have been brought together, do not move them until
the adhesive is cured. The assembly can be held
together with clamps, rivets, etc. A faster cure can be
obtained by heating with a heat lamp or heat gun.
After the parts have been bonded and have had time
to cure, rough sand the seam and apply the final
adhesive filler to the area being repaired. Smooth the
filler with a spreader, wooden tongue depressor, or
squeegee. For fine texturing, a small amount of
water can be applied to the filler surface while
smoothing. The cured filler can be sanded as neces-
sary and, as a final step, cleanup can be done with
soapy water. Wipe the surface clean with a dry cloth
allowing time for the panel to dry before moving on
with the repair.
PANEL REINFORCEMENT
Structural repair procedures for rigid panels with
large cracks and holes will require a reinforcement
backing. Reinforcements can be made with several
applications of glass cloth saturated with structural
adhesive. Semi-rigid or flexible repair materials
should be used for semi-rigid or flexible backing rein-
forcement (Fig. 2) and (Fig. 3). Open meshed fiber-
glass
dry
wall
tape
can
be
used
to
form
a
reinforcement. The dry wall tape allows the resin to
penetrate through and make a good bond between
the panel and the adhesive. Structurally, the more
dry wall tape used, the stronger the repair.
Another kind of repair that can be done to repair
large cracks and holes is to use a scrap piece of sim-
ilar plastic and bond with structural adhesive. The
reinforcement should cover the entire break and
should have a generous amount of overlap on either
side of the cracked or broken area.
When repairing plastic, the damaged area is first
“V’d” out, or beveled. Large bonding areas are desir-
able when repairing plastic because small repairs are
less likely to hold permanently. Beveling the area
around a crack at a 20 degree angle will increase the
bonding surface for a repair (Fig. 4). It is recom-
mended that sharp edges be avoided because the joint
may show through after the panel is refinished.
Fig. 1 PANEL SECTIONING
1 - EXISTING PANEL
2 - NEW PANEL
3 - PANEL ADHESIVE
4 - BONDING STRIP
Fig. 2 SOFTENED EDGES
1 - SOFTENED EDGES
2 - PANEL ADHESIVE
3 - BONDING STRIP
Fig. 3 PANEL REINFORCEMENT
1 - PANEL ADHESIVE
2 - REINFORCEMENT
23 - 6
BODY
RS
BODY (Continued)
• Panel repair for both flexible and rigid panels
are basically the same. The primary difference
between flexible panel repair and rigid panel repair
is in the adhesive materials used (Fig. 5).
• The technician should first decide what needs to
be done when working on any type of body panel.
One should determine if it is possible to return the
damage part to its original strength and appearance
without exceeding the value of the replacement part.
• When plastic repairs are required, it is recom-
mended that the part be left on the vehicle when
every possible. That will save time, and the panel
will remain stationary during the repair. Misalign-
ment can cause stress in the repair areas and can
result in future failure.
VISUAL INSPECTION
Composite materials can mask the severity of an
accident. Adhesive bond lines, interior structure of
the doors, and steel structures need to be inspected
carefully to get a true damage assessment. Close
inspection may require partial removal of interior
trim or inner panels.
Identify the type of repair: Puncture or Crack -
Damage that has penetrated completely through the
panel. Damage is confined to one general area; a
panel section is not required. However, a backer
panel, open fiberglass tape, or matted material must
be bonded from behind (Fig. 7) (Fig. 6).
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achieve a successful repair. All spider
web cracks leading away from a damaged area must
be stopped or removed. To stop a running crack in a
panel, drill a 6 mm (0.250 in.) hole at the end of the
crack farthest away from the damage. If spider web
cracks can not be stopped, the panel would require
replacement. The surfaces around the damaged area
should be stripped of paint and freed from wax and
oil. Scuff surfaces around repair area with 360 grit
wet/dry sandpaper, or equivalent, to assure adhesion
of repair materials.
PATCHING PANELS
An panel that has extensive puncture type damage
can be repaired by cutting out the damaged material
(Fig. 7). Use a suitable reciprocating saw or cut off
wheel to remove the section of the panel that is dam-
aged. The piece cut out can be used as a template to
shape the new patch. It is not necessary to have
access to the back of the panel to install a patch.
Bevel edges of cutout at 20 degrees to expose a larger
bonding area on the outer side. This will allow for an
increased reinforcement areas.
PANEL PATCH FABRICATIONS
A patch can be fabricated from any rigid fiberglass
panel that has comparable contour with the repair
area. Lift gates and fenders can be used to supply
patch material. If existing material is not available
or compatible, a patch can be constructed with adhe-
sive and reinforcement mesh (dry wall tape). Perform
the following operation if required:
Fig. 4 BEVELING ANGLE - 20 DEGREE
Fig. 5 FIBERGLASS TAPE
Fig. 6 DAMAGE COMPONENT
1 - PUNCTURE
RS
BODY
23 - 7
BODY (Continued)
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