Frelander 2. Manual — part 665
2. Drill holes in the new panel ready for MIG plug welding.
3. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step, if not, rectify and
recheck before proceeding.
4. Spot weld.
5. MIG plug weld.
6. Apply adhesive to the rear lamp mounting panel sections at
the points illustrated.
7. Offer up the rear lamp mounting panel sections and clamp into
position. Check alignment, if correct, proceed to next step, if
not, rectify and recheck before proceeding.
8. Tack weld the butt joints.
9. MIG plug weld.
10. Dress the tack welds.
11. MIG weld the butt joint.
12. Dress all welded joints.
13. The installation of associated panels and mechanical
components is the reverse of removal.
Rear End Sheet Metal Repairs - Rear Crossmember
Removal and Installation
Removal
• NOTE: The rear crossmember is serviced as a separate weld-on panel.
• NOTE: The panel is serviced less its weld studs.
1. The rear crossmember is replaced in conjunction with:
Rear bumper cover
Rear bumper armature
Back panel
Inner back panel assembly
Spare wheel well
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 spare wheel well.
For additional information, refer to:
Spare Wheel Well
(501-30
Rear 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.
2. Offer up the new panel and clamp into position. Check
alignment, if correct, proceed to next step, if not, rectify and
recheck before proceeding.
3. Spot weld.
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