Frelander 2. Manual — part 658
Side Panel Sheet Metal Repairs - Rocker Panel
Removal and Installation
Removal
CAUTION: The rocker panel must be MIG slot brazed to the rocker panel inner reinforcement, which is DP600, (Dual
Phase steel). MIG plug welds / spot welds must not be used.
• NOTE: The rocker panel is serviced as a separate weld-on panel.
1. The rocker panel is replaced in conjunction with:
Front bumper cover
Front fender
Front door
Rear door
2. For additional information relating to this repair procedure
please see the following:
For additional information, refer to:
Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
Standard Workshop Practices
(100-00 General Information,
Description and Operation).
3. Remove the fender.
4. Remove the front door.
For additional information, refer to:
Front Door
(501-03 Body
Closures, Removal and Installation).
5. Remove the rear door.
For additional information, refer to:
Rear Door
(501-03 Body
Closures, Removal and Installation).
6. Remove the front road wheel.
For additional information, refer to:
Wheel and Tire
(204-04
Wheels and Tires, Removal and Installation).
7. Remove the rear road wheel.
For additional information, refer to:
Wheel and Tire
(204-04
Wheels and Tires, Removal and Installation).
8. LH side: Remove the hood release handle.
9. Remove the front seat.
For additional information, refer to:
Front Seat
(501-10
Seating, Removal and Installation).
10. Remove the floor console.
For additional information, refer to:
Floor Console
(501-12
Instrument Panel and Console, Removal and Installation).
11. Remove the front door aperture weatherseal.
12. Remove the rear door aperture weatherseal.
13. Remove the cowl side trim panel.
For additional information, refer to:
Cowl Side Trim Panel
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
14. Remove the B-Pillar upper trim.
For additional information, refer to:
B-Pillar Upper Trim Panel
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
15. Remove the RH & LH B-Pillar lower trims.
For additional information, refer to:
B-Pillar Lower Trim Panel
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
16. Remove the rear quarter trim panel.
For additional information, refer to:
Rear Quarter Trim Panel
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
17. Remove the RH & LH rocker panel inner trims.
18. Remove the rocker panel outer moulding.
19. Remove the back panel inner trim.
20. Remove the rear seat cushion.
For additional information, refer to:
Rear Seat Cushion
(501-10
Seating, Removal and Installation).
21. Remove the front safety belt retractor.
For additional information, refer to:
Front Safety Belt Retractor
(501-20A Safety Belt System, Removal and Installation).
22. Remove the rear carpet section.
23. Release and lay aside the front carpet section.
24. Remove the B-Pillar side impact sensor.
For additional information, refer to:
B-Pillar Side Impact Sensor
(501-20B Supplemental Restraint System, Removal and
Installation).
25. Remove the C-Pillar side impact sensor.
For additional information, refer to:
C-Pillar Side Impact Sensor
(501-20B Supplemental Restraint System, Removal and
Installation).
26. Release and lay aside the bulkhead inner insulation.
27. Release and lay aside the wiring harness along the inner
rocker panel.
28. Saw cut the old panel at its joints with the A-Pillar, B-Pillar
and quarter panel, ensuring there is an allowance for the
new panel to overlap. Use the new panel for reference.
29. Mill out the spot welds.
30. Separate the joints and remove the old panel.
Installation
1. Offer up and align the new panel and clamp into position,
overlapping the old panel remaining on the vehicle.
2. Saw cut through the new and old panels at the A-Pillar,
B-Pillar and quarter panel, where the MIG butt joints are to
be made.
3. Remove the new panel and the old remnants.
4. NOTE: MIG slots should be installed in accordance with the
spacing shown in the illustration. Where this is not possible,
due to the indents in the panel, the slot should be made in the
location of the original spot weld.
Cut slots in the new panel ready for MIG brazing.
5. Prepare the old and new panel joint surfaces.
6. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step, if not, rectify and
recheck before proceeding.
7. Tack weld the butt joints.
8. MIG braze the slots.
9. Dress the tack welds.
10. MIG weld the butt joints.
11. Dress all welded joints.
Rear End Sheet Metal Repairs - Rear End Sheet Metal
Description and Operation
Rear end service panels
Item
Description
1
Inner quarter panel front
2
Inner quarter panel rear
3
Inner quarter panel
4
Rear wheelhouse outer
5
Water drain panel section
6
Rear lamp mounting panel
7
Rear bumper cover
8
Rear bumper
9
Quarter panel
10
Back panel assembly
11
Back panel
12
Spare wheel well
13
Rear crossmember
14
Rear wheelhouse front extension
15
Rear side member closing panel
16
Rear side member upper side extension
17
Rear side member lower side extension
18
Rear side member section
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