Mitsubishi Galant (2004+). Manual — part 37

BODY REPAIR

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9-27

CAUTION

•

Be careful not to file too much; this will reduce the
strength and rigidity of the panel.

•

Do not use the file in one direction only; alternate use
in two directions diagonally opposite each other.

4. Next, file the area so that convex and concave parts are no

longer clearly visible, and at the same time remove small
projections.

5. After once again smoothing the clearly visible dents and

projections by using the hammer and dolly, follow step 4
above.
Alternately repeat hammering and filing until there are file
traces over the entire repair area.

6. Make a solder build-up at the repair.
7. Finally, finish up the solder build-up using a body file.

USING A FRAME STRAIGHTENER

M4090013000022

For serious and extensive damage, when for exam-
ple the damage extends to the frame of members, it
is necessary to first use a frame straightener to make
a rough, overall repair of the body, and then to pro-
ceed to careful repairs of each individual area of
damage. When a frame straightener is used for body
repairs, it is a fundamental principle that the pulling
should be in the direction from which the impact was
sustained, and from the opposite direction. If this is,
in error, not done, previously undamaged compo-
nents will be deformed, and repair may become
impossible.
It is for that reason that it is important to decide upon
the method of repair, especially regarding the initial
overall repair, by following the steps below.

OVERALL ROUGH REPAIRS

1. First, analyze the impact. This means analysis

and consideration of the point of collision, the
speed at the time of collision, and the strength,
weight and shape of the object hit.

2. Then get a complete understanding of the

condition of the existing damage. In particular, if
the damage extends to the suspension installation
components, an inspection must be made to
determine whether or not there is any deviation of
the frame or body alignment.

3. Finally, determine what repair methods should be

used.

•

To what extent will frame straightening and other
overall repairs be necessary in order to restore
the damaged areas to the way they were?

•

At what stage of the repairs should panels adjoin-
ing the components to be frame straightened,
etc., be removed?

•

Decide upon the work steps and restoration
methods to be followed after the rough, overall
repairs are completed.

Select the frame straightener based upon the results
of above, and use it to pull in the appropriate direc-
tion. More than one direction may be appropriate,
depending upon the damage.
If the damage is of a moderate degree or less, it may
be possible to do all that is necessary in one pull.
If, however, the damage is major, that is to say if
repairs must be made to components of the passen-
ger compartment such as the dash panel, etc., it may
be necessary, after completing the first pull, to set up
the frame straightener at a different position and use
it again at that position.

AB200102

BODY REPAIR

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BASE OF BODY REPAIR

9-28

FRAME STRAIGHTENING NOTES

•

For safety, no one must be standing in the direction of the
pull.

•

Wires or chains should be used for protection in the event
of an accident.

•

For frame straightening of body with frame, care should be
taken regarding the position (body mount) of installation to
the frame. The reason for this is that usually mounting rub-
ber pieces are used at the installation part in order to
improve vibration prevention, and these mounting rubber
pieces might be deformed if there is a deviation of the
installation position.

•

If the part to be pulled is made of high-tensile steel (which
has a higher tensional strength and yield point than ordinary
steel), the pulling must be done with care in order to avoid
"overpull" and "springback." It is particularly important for
the pulling of sidemembers and other reinforcement compo-
nents made of high-tensile steel that the pulling not be all
done at one time; pull gradually while using a hammer to
repair distorted areas as the pulling is done.

FRAME REPAIR PROCEDURES

M4090014000025

The frame is subjected to the following types of
loads.

•

Vertical loads.. Vertical loads may occur either
while stopped or during travel.

•

Lateral (horizontal) loads.. This type of loads
occurs during turning, start-off and braking.

•

Torsional loads.. Torsional loads occur while trav-
eling on roads with poor surface conditions.

These various types of loads are compounded under
various conditions, and are applied to the frame.
As a result, it is important, before attempting to repair
the frame, to carefully observe the shape of the dam-
aged part and to in that way fully understand the
cause of the damage.

CHECKING FOR FRAME CRACKING OR
FLANKING

Check, by using a test hammer, for flaking or cracking of the
welded surface of the sidemembers, crossmembers and brack-
ets.

AB200103AB

WIRES FOR
PROTECTION

AB200127AB

TEST HAMMER

SIDEMEMBER

BODY REPAIR

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REPAIRING CRACKS

If the check reveals a crack(s) in the frame, repair as described
bellow.
1. Remove the components near the crack.
2. Make

φ

6

−

8 mm (0.2

−

0.3 inch) holes (to prevent further

cracking), by using a drill, at points 7

−

8 mm (0.3 inch) from

the crack ends.

3. Use a

φ

10

−

12 mm (0.4

−

0.5 inch) drill to bevel the hole

openings.

4. Use a chisel or gouging tool to open up the crack and holes,

and then fill the crack and holes by MIG welding.

CAUTION

•

Gas welding should be avoided because it causes ther-
mal distortion of the frame.

•

When using a grinder for finishing, be careful not to
grind the frame excessively.

5. Using a grinder for finishing after welding.

AB301469

CRACK-STOP HOLE

CRACK

A

A

Ø6 – 8 mm
(0.2 – 0.3 in)

A : 7 – 8 mm (0.3 in)

AB

AB301470AB

Ø10 – 12 mm
(0.4 – 0.5 in)

Ø10

–

12 mm (0.4

–

0.5 in)

Ø6

–

8 mm

(0.2

–

0.3 in)

AB301471AB

CRACK

CRACK-STOP
HOLE

APPROX.
8 mm
(0.3 in)

APPROX.
1 mm
(0.04 in)

APPROX.
1 mm
(00.4 in)

APPROX.

90˚

IF A CHISEL
IS USED

IF A GOUGE
IS USED

A

A

A

AB200131AB

BODY REPAIR

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CAUTION

•

The reinforcement plate should completely cover the
cracked part.

•

The reinforcement plate should be the same thickness
and material as the frame.

6. To avoid a concentration of stress, prepare a reinforcement

plate that has been cut to 30

−

45 degree angle at both

ends.

CAUTION

Be sure that the edges of the reinforcement plate are not
near any place where a concentration of stress of the
crossmember or spring hanger installation part, etc. could
easily occur.
7. Attach the reinforcement plate to the repaired crack area by

MIG welding. In order to avoid a concentration of stress at
the time, weld the reinforcement plate at points about 10 mm
(0.4 inch) from its edges.

NOTE: If the crack is at the upper side of the frame, attach
the reinforcement plate facing downward, as shown in (1).
If the crack is at the lower side, attach the reinforcement
plate to face upward, as shown in (2).

8. Finally, apply a coating of chassis black to the repaired area

and to any places where the coating has flaked off.

AB301461

A

A

A : 30 – 45˚

AB

AB200133

AB200133

10 mm (0.4 in)

WELDED POINT

AB

AB200134

AB200134AB

(2)

(1)