Chrysler Town, Dodge Caravan. Manual — part 436
(1) Cover waxed paper or plastic with adhesive
backed nylon mesh (dry wall tape) larger than the
patch required (Fig. 8).
(2) Tape waxed paper or plastic sheet with mesh to
a surface that has a compatible contour to the repair
area.
(3) Apply a liberal coat of adhesive over the rein-
forcement mesh (Fig. 8). If necessary apply a second
or third coat of adhesive and mesh after firs coat has
cured. The thickness of the patch should be the same
as the repair area.
(4) After patch has cured, peel waxed paper or
plastic from the back of the patch.
(5) If desired, a thin film coat of adhesive can be
applied to the back of the patch to cover mesh for
added strength.
PANEL PATCH INSTALLATION
(1) Make a paper or cardboard pattern the size
and shape of the cutout hole in the panel.
(2) Trim 3 mm (0.125 in.) from edges of pattern so
patch will have a gap between connecting surfaces.
(3) Using the pattern as a guide, cut the patch to
size.
(4) Cut scrap pieces of patch material into 50 mm
(2 in.) squares to use as patch supports to sustain
the patch in the cutout.
(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in
from edge of cutout hole (Fig. 7).
(6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.)
away from edge of patch across from holes drilled
around cutout.
(7) Drill 3 mm (0.125 in.) holes in the support
squares 13 mm (0.5 in.) from the edge in the center
of one side.
(8) Scuff the backside of the body panel around the
cutout hole with a scuff pad or sandpaper.
(9) Mix enough adhesive to cover one side of all
support squares.
(10) Apply adhesive to cover one side of all support
squares.
(11) Using number 8 sheet metal screws, secure
support squares to back side of body panel with
adhesive sandwiched between the panel and squares
(Fig. 9).
(12) Position patch in cutout against support
squares and adjust patch until the gap is equal along
all sides (Fig. 10).
(13) Drill 3 mm (0.125 in.) holes in the support
squares through the pre-drilled holes in the patch.
(14) Apply a coat of adhesive to the exposed ends
of the support squares (Fig. 11).
Fig. 7 DAMAGED PANEL CUTOUT AND PATCH
1 - CUTOUT
2 - DAMAGED BODY PANEL
3 - 4 MM (0.160 IN.) HOLES
4 - PATCH CUT TO SIZE
Fig. 8 FABRICATED PANEL
1 - STRUCTURAL ADHESIVE
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 - WIDTH OF V-GROOVE
4 - WAXED PAPER
Fig. 9 SECURE SUPPORT SQUARES TO BODY PANEL
1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
23 - 8
BODY
RS
BODY (Continued)
(15) Install screws to hold the patch to support
squares (Fig. 12). Tighten screws until patch surface
is flush with panel surface.
(16) Allow adhesive to cure, and remove all screws.
(17) Using a 125 mm (5 in.) 24 grit disc grinder,
grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the
patch (Fig. 13). With compressed air, blow dust from
around patch.
(18) Apply adhesive backed nylon mesh (dry wall
tape) over gaps around patch (Fig. 14).
(19) Mix enough adhesive to cover the entire patch
area.
(20) Apply adhesive over the mesh around patch,
and smooth epoxy with a wide spreader to reduce fin-
ish grinding. Use two to three layers of mesh and
adhesive to create a stronger repair (Fig. 15).
PATCHED PANEL SURFACING
After patch panel is installed, the patch area can
be finished using the same methods as finishing
other types of body panels. If mesh material is
exposed in the patched area, grind surface down, and
apply a coat of high quality rigid plastic body filler.
Prime, block sand, and paint as required.
Fig. 10 POSITION PATCH IN CUTOUT AND ALIGN
1 - CUTOUT
2 - SUPPORT SQUARES
Fig. 11 APPLY ADHESIVE TO SUPPORT SQUARES
1 - APPLICATOR
2 - SUPPORT SQUARES
3 - ADHESIVE
Fig. 12 INSTALL SCREWS
1 - PATCH
2 - GAP
Fig. 13 GRIND SURFACE
1 - PATCH
2 - GAP
3 - DISC GRINDER
RS
BODY
23 - 9
BODY (Continued)
STANDARD PROCEDURE - HEAT STAKING
(1) Remove trim panel.
(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt
the
material
securing
the
components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
Fig. 14 COVER GAPS WITH MESH
1 - GROUND DOWN AREA
2 - PATCH
3 - MESH
Fig. 15 COVER MESH WITH ADHESIVE
1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER
23 - 10
BODY
RS
BODY (Continued)
SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
All seat belt anchor bolts
39
29
—
Armrest shoulder bolt
29
21
—
Bench seat riser bolts
48
35
—
Bench seat track nuts
48
35
—
Quad bucket seat track to cushion frame bolts
40
30
—
Bucket seat back pivot bolts
33
24
—
Center seat to seat track bolts
24
17
—
Child seat module screws (bench seats)
7
—
62
Child seat module screws (quad seats)
13.5
10
—
Crossmember to radiator closure panel bolts
28
21
—
Door check strap to door end frame
12
—
105
Door latch to door end frame bolts
10
—
89
Floor latch to seat cushion frame bolts
27
19
—
Front cover to seat track screws
4
—
32
Front door hinge to hinge pillar bolts
34
25
—
Front door hinge to door nuts and bolts
34
25
—
Front door latch striker bolts
28
21
—
Front/quad seat cushion bolts
28.5
21
—
Front seat belt retractor bolts
38
28
—
Front seat riser to floor nuts
60
44
—
Front seat track cover screws
4
—
35
Front seat riser to seat track nuts
81
60
—
Front seatback pivot bolts
54
40
—
Front seatback recliner nut
12
—
105
Front seatback assist strap screws
2.5
—
22
Grocery bag holder screws
2
—
17
Hinge to liftgate bolts
33
24
—
Hood latch to bolts
13.5
10
—
Hood latch striker bolts
13.5
10
—
Hood hinge to hood bolts
13.5
10
—
Liftgate exterior handle outer screws
20
15
—
Liftgate exterior handle inner bolts
40
30
—
Lifgate hinge to roof header bolts
33
24
—
Liftgate latch bolts
16
12
—
Liftgate latch striker bolts
28
21
—
Liftgate lift motor link to liftgate
28
21
—
Liftgate spoiler bolts
9
—
80
Lifgate stabilizer wedge striker to D-pillar bolts
3
—
30
RS
BODY
23 - 11
BODY (Continued)
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