Frelander 2. Manual — part 661
Rear End Sheet Metal Repairs - Rear Side Member Section
Removal and Installation
Removal
• NOTE: The rear side member section is cut from the rear side member service panel. The section is approximately
410mm in length and is serviced with the rear side member lower extension.
• NOTE: It is necessary to remove the spare wheel well to allow access to the rear side member section.
1. The rear side member section is replaced in conjunction with:
Rear bumper cover
Rear bumper armature
Back panel
Rear bumper mounting
Inner back panel assembly
Rear side member closing panel.
Spare wheel well
Fuel tank
Rear subframe and suspension 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 rear side member closing panel.
For additional information, refer to:
Rear Side Member Closing
Panel
(501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
4. Remove the rear subframe / suspension as an assembly.
For additional information, refer to:
Rear Subframe
(502-00
Uni-Body, Subframe and Mounting System, Removal and
Installation).
5. Remove the fuel tank.
For additional information, refer to:
Fuel Tank
(310-01A Fuel
Tank and Lines - I6 3.2L Petrol, Removal and Installation).
6. Mill out the spot welds.
7. Saw cut the old panel at the point illustrated.
8. Separate the joints and remove the old panel.
Installation
1. NOTE: Ensure there is a 50mm minimum stagger between
the old side member and the new reinforcement section cuts.
Remove a section of reinforcement from the old panel:
1. Saw cut the reinforcement at the point illustrated,
do not cut through the side member.
2. Mill out 5 spot welds.
3. Separate and remove the reinforcement remnant.
2. NOTE: Ensure there is a 50mm minimum stagger between
the old side member and the new reinforcement section
cuts.
Remove the rear side member section from the service
panel:
1. Saw cut the side member at the point
illustrated, do not cut through the
reinforcement.
2. Mill out 5 spot welds.
3. Saw cut the reinforcement at the point
illustrated.
4. Separate and remove the side member section.
3. Prepare the old and new panel joint surfaces.
4. Drill holes in the new panel ready for MIG plug welding.
5. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step, if not, rectify and
recheck before proceeding.
6. With panels clamped into position, tack weld the butt
joints.
7. Dress the tack welds.
8. MIG weld the butt joints.
9. MIG plug weld.
10. Dress all welded joints.
11. The installation of associated panels and mechanical
components is the reverse of removal.
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