Frelander 2. Manual — part 644
Front End Sheet Metal Repairs - Front Side Member Closing Panel
Removal and Installation
Removal
• NOTE: The front side member closing panel must be unpicked from the front side member and suspension top mount
assembly, it is not serviced separately.
• NOTE: The panel is serviced less its weld studs
1. The front side member closing panel is replaced in conjunction
with:
Front bumper cover
Front bumper
Hood latch panel
Both front fenders
Front bumper mounting
Fender apron lower panel
Fender apron panel front reinforcement
Front side member
• NOTE: It is also necessary to remove the engine and suspension as an assembly.
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 front side member.
For additional information, refer to:
Front Side Member
(501-27
Front End Sheet Metal Repairs, Removal and Installation).
4. Mill out the spot welds.
5. Saw cut the old panel at the point illustrated.
6. Separate the joints and remove the old panel.
Installation
1. Remove the panel from the service panel.
1. Mill out the spot welds.
2. Saw cut, ensuring the cut aligns with the one
already made on the vehicle.
2. Prepare the old and new panel joint surfaces.
3. Drill holes in the new panel ready for MIG plug welding.
4. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step, if not, rectify and
recheck before proceeding.
5. With panels clamped into position:
1. Tack weld the butt joint.
2. MIG plug weld.
6. Dress the tack welds.
7. MIG weld the butt joint.
8. Install weld stud.
9. Dress all welded joints.
10. The installation of associated panels and mechanical
components is the reverse of removal.
Front End Sheet Metal Repairs - Fender Apron Panel Front Reinforcement
Removal and Installation
Removal
• NOTE: The fender apron panel front reinforcement has to be removed from the fender apron panel service panel; it is not
available as a separate panel.
• NOTE: The panel is serviced less its weld studs
1. The front side member and fender apron panel is replaced in
conjunction with:
Front bumper cover
Front bumper
Hood
Hood latch panel
Both front fenders
Fender apron lower panel
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 apron lower panel.
For additional information, refer to:
Fender Apron Lower Panel
(501-27 Front End Sheet Metal Repairs, Removal and
Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
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