Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 478

will remain stationary during the repair. Misalign-
ment can cause stress in the repair areas and can
result in future failure.

VISUAL INSPECTION

Composite materials can mask the severity of an

accident. Adhesive bond lines, interior structure of
the doors, and steel structures need to be inspected
carefully to get a true damage assessment. Close
inspection may require partial removal of interior
trim or inner panels.

Identify the type of repair: Puncture or Crack -

Damage that has penetrated completely through the
panel. Damage is confined to one general area; a
panel section is not required. However, a backer
panel, open fiberglass tape, or matted material must
be bonded from behind (Fig. 7) (Fig. 6).

PANEL SURFACE PREPARATION

If a body panel has been punctured, cracked, or

crushed, the damaged area must be removed from
the panel to achieve a successful repair. All spider
web cracks leading away from a damaged area must
be stopped or removed. To stop a running crack in a
panel, drill a 6 mm (0.250 in.) hole at the end of the
crack farthest away from the damage. If spider web
cracks can not be stopped, the panel would require
replacement. The surfaces around the damaged area
should be stripped of paint and freed from wax and

oil. Scuff surfaces around repair area with 360 grit
wet/dry sandpaper, or equivalent, to assure adhesion
of repair materials.

PATCHING PANELS

An panel that has extensive puncture type damage

can be repaired by cutting out the damaged material
(Fig. 7). Use a suitable reciprocating saw or cut off
wheel to remove the section of the panel that is dam-
aged. The piece cut out can be used as a template to
shape the new patch. It is not necessary to have
access to the back of the panel to install a patch.
Bevel edges of cutout at 20 degrees to expose a larger
bonding area on the outer side. This will allow for an
increased reinforcement areas.

PANEL PATCH FABRICATIONS

A patch can be fabricated from any rigid fiberglass

panel that has comparable contour with the repair
area. Lift gates and fenders can be used to supply
patch material. If existing material is not available
or compatible, a patch can be constructed with adhe-
sive and reinforcement mesh (dry wall tape). Perform
the following operation if required:

(1) Cover waxed paper or plastic with adhesive

backed nylon mesh (dry wall tape) larger than the
patch required (Fig. 8).

(2) Tape waxed paper or plastic sheet with mesh to

a surface that has a compatible contour to the repair
area.

(3) Apply a liberal coat of adhesive over the rein-

forcement mesh (Fig. 8). If necessary apply a second
or third coat of adhesive and mesh after firs coat has
cured. The thickness of the patch should be the same
as the repair area.

(4) After patch has cured, peel waxed paper or

plastic from the back of the patch.

Fig. 5 FIBERGLASS TAPE

Fig. 6 DAMAGE COMPONENT

1 - PUNCTURE

Fig. 7 DAMAGED PANEL CUTOUT AND PATCH

1 - CUTOUT
2 - DAMAGED BODY PANEL
3 - 4 MM (0.160 IN.) HOLES
4 - PATCH CUT TO SIZE

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(5) If desired, a thin film coat of adhesive can be

applied to the back of the patch to cover mesh for
added strength.

PANEL PATCH INSTALLATION

(1) Make a paper or cardboard pattern the size

and shape of the cutout hole in the panel.

(2) Trim 3 mm (0.125 in.) from edges of pattern so

patch will have a gap between connecting surfaces.

(3) Using the pattern as a guide, cut the patch to

size.

(4) Cut scrap pieces of patch material into 50 mm

(2 in.) squares to use as patch supports to sustain
the patch in the cutout.

(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in

from edge of cutout hole (Fig. 7).

(6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.)

away from edge of patch across from holes drilled
around cutout.

(7) Drill 3 mm (0.125 in.) holes in the support

squares 13 mm (0.5 in.) from the edge in the center
of one side.

(8) Scuff the backside of the body panel around the

cutout hole with a scuff pad or sandpaper.

(9) Mix enough adhesive to cover one side of all

support squares.

(10) Apply adhesive to cover one side of all support

squares.

(11) Using number 8 sheet metal screws, secure

support squares to back side of body panel with
adhesive sandwiched between the panel and squares
(Fig. 9).

(12) Position patch in cutout against support

squares and adjust patch until the gap is equal along
all sides (Fig. 10).

(13) Drill 3 mm (0.125 in.) holes in the support

squares through the pre-drilled holes in the patch.

(14) Apply a coat of adhesive to the exposed ends

of the support squares (Fig. 11).

(15) Install screws to hold the patch to support

squares (Fig. 12). Tighten screws until patch surface
is flush with panel surface.

(16) Allow adhesive to cure, and remove all screws.
(17) Using a 125 mm (5 in.) 24 grit disc grinder,

grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the
patch (Fig. 13). With compressed air, blow dust from
around patch.

(18) Apply adhesive backed nylon mesh (dry wall

tape) over gaps around patch (Fig. 14).

(19) Mix enough adhesive to cover the entire patch

area.

(20) Apply adhesive over the mesh around patch,

and smooth epoxy with a wide spreader to reduce fin-
ish grinding. Use two to three layers of mesh and
adhesive to create a stronger repair (Fig. 15).

Fig. 8 FABRICATED PANEL

1 - STRUCTURAL ADHESIVE
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 - WIDTH OF V-GROOVE
4 - WAXED PAPER

Fig. 9 SECURE SUPPORT SQUARES TO BODY

PANEL

1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL

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Fig. 10 POSITION PATCH IN CUTOUT AND ALIGN

1 - CUTOUT
2 - SUPPORT SQUARES

Fig. 11 APPLY ADHESIVE TO SUPPORT SQUARES

1 - APPLICATOR
2 - SUPPORT SQUARES
3 - ADHESIVE

Fig. 12 INSTALL SCREWS

1 - PATCH
2 - GAP

Fig. 13 GRIND SURFACE

1 - PATCH
2 - GAP
3 - DISC GRINDER

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PATCHED PANEL SURFACING

After patch panel is installed, the patch area can

be finished using the same methods as finishing
other types of body panels. If mesh material is
exposed in the patched area, grind surface down, and
apply a coat of high quality rigid plastic body filler.
Prime, block sand, and paint as required.

STANDARD PROCEDURE - BUZZ, SQUEAK &
RATTLE

Buzz, Squeak & Rattles (BSR) may be caused by

any one or more of the following and may be cor-
rected as indicated:

• Loose fasteners should be tightened to specifica-

tions.

• Damaged or missing clips should be replaced.

• Damaged trim panels should be replaced.

• Incorrectly installed trim panels should be rein-

stalled properly.

Many BSR complaints such as loose trim, can be

serviced using the Mopar

t Parts BSR Noise Reduc-

tion Kit. This kit contains various tapes including
foam, flock and anti-squeak used to eliminate noises
caused by metal, plastic and vinyl components. Long
life lubricants and greases can also be used on a vari-
ety of components. Refer to the Buzz, Squeak & Rat-
tle Kit table for material contents and usage.

BUZZ, SQUEAK & RATTLE KIT

ITEM

FEATURES

APPLICATIONS

SERVICE TEMP

Itch And Squeak
Tape

An abrasion resistant material
thin enough to conform to
most irregular surfaces. Stops
most itches and squeaks.

Between metal and metal, met-
al and plastic, metal and vinyl,
vinyl and plastic. Interior.
Examples: Trim panels and
bezels.

-40° to 225° Fahr-
enheit
(-40° to 107° Cel-
sius)

Black Nylon Flock

Nylon Flock with an aggressive
acrylic adhesive. Provides for
cushioning and compression fit,
also isolates components. Wa-
ter-resistant.

Between metal and metal, met-
al and plastic, vinyl and plastic.
Examples: Pull cups, bezels,
clips, ducts, top cover to glass,
cowl panel.

-40° to 180° Fahr-
enheit
(-40° to 82° Celsius)

Fig. 14 COVER GAPS WITH MESH

1 - GROUND DOWN AREA
2 - PATCH
3 - MESH

Fig. 15 COVER MESH WITH ADHESIVE

1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER

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