Frelander 2. Manual — part 666
4. Install weld studs.
5. Dress all welded joints.
6. The installation of associated panels and mechanical
components is the reverse of removal.
Rear End Sheet Metal Repairs - Rear Side Member Lower Side Extension
Removal and Installation
Removal
• NOTE: The rear side member lower side extension is serviced as a separate weld-on panel, it is also serviced as part of
the rear side member.
1. The rear side member lower side extension is replaced in
conjunction with:
Rear bumper cover
Rear bumper armature
Rear lamp mounting 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 rear lamp mounting panel.
For additional information, refer to:
Rear Lamp Mounting Panel
(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. MIG plug weld.
4. Dress all welded joints.
5. The installation of associated panels and mechanical
components is the reverse of removal.
Rear End Sheet Metal Repairs - Rear Lamp Mounting Panel
Removal and Installation
Removal
• NOTE: The rear lamp mounting panel is serviced as a separate weld-on panel.
• NOTE: There are NVH elements attached to the old panel, they are not serviced on the new panel. If damaged, new
elements will be required.
1. The rear lamp mounting panel is replaced in conjunction with:
Rear bumper cover
Rear bumper armature
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 bumper.
For additional information, refer to:
Rear Bumper
(501-19
Bumpers, Removal and Installation).
4. Disconnect both battery cables.
5. Remove the D-Pillar trim panel.
For additional information, refer to:
D-Pillar Trim Panel
(501-05
Interior Trim and Ornamentation, Removal and Installation).
6. Remove the rear wheel and tire.
7. Remove the rear quarter window moulding.
8. Remove the loadspace trim panel.
9. Remove the forced air extraction grille.
10. Release the insulating material and lay aside.
11. Release and lay aside the wiring harness.
12. Use a belt sander to sand down the spot welds in the area
illustrated.
13. Mill out the remaining spot welds.
14. Separate the joints and remove the old panel, also releasing
the NVH elements.
Installation
1. Prepare the old and new panel joint surfaces, including the
rear lamp mounting panel sections.
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. Remove the new panel.
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