Dodge Durango (HB). Manual — part 1374
PATCHING PANELS
An panel that has extensive puncture type damage
can be repaired by cutting out the damaged material.
Use a suitable reciprocating saw or cut off wheel to
remove the section of the panel that is damaged. 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 rein-
forcement 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 adhesive
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.
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 reinforce-
ment mesh. If necessary apply a second or third
coat of adhesive and mesh after first 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.
5. If desired, a thin film coat of adhesive can be applied to the back of the patch to cover mesh for added strength.
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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 sur-
faces.
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.
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 sand-
wiched between the panel and squares.
12. Position patch in cutout against support squares
and adjust patch until the gap is equal along all
sides.
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.
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15. Install screws to hold the patch to support
squares. 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. With compressed air, blow dust from
around patch.
18. Apply adhesive backed nylon mesh (dry wall tape)
over gaps around patch.
19. Mix enough adhesive to cover the entire patch
area.
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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.
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.
BUZZ, SQUEAK & RATTLE
Buzz, Squeak & Rattles (BSR) may be caused by any one or more of the following and may be corrected as indi-
cated:
•
Loose fasteners should be tightened to specifications.
•
Damaged or missing clips should be replaced.
•
Damaged trim panels should be replaced.
•
Incorrectly installed trim panels should be reinstalled properly.
Many BSR complaints such as loose trim, can be serviced using the Mopar
T
Parts BSR Noise Reduction 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 variety of components. Refer to the
Buzz, Squeak & Rattle 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,
metal and plastic, metal and
vinyl, vinyl and plastic. Interior.
Examples: Trim panels and
bezels.
-40° to 225°
Fahrenheit
(-40° to 107°
Celsius)
Black Nylon Flock
Nylon Flock with an aggressive
acrylic adhesive. Provides for
cushioning and compression fit,
also isolates components.
Water-resistant.
Between metal and metal,
metal and plastic, vinyl and
plastic.
Examples: Pull cups, bezels,
clips, ducts, top cover to glass,
cowl panel.
-40° to 180°
Fahrenheit
(-40° to 82° Celsius)
High Density
Urethane Foam
Tear resistant, highly resilient
and durable.
Between metal and metal,
metal and plastic. Water-
resistant.
Examples: I/P, heavy metal
rattles, isolating brackets.
-40° to 180°
Fahrenheit
(-40° to 82° Celsius)
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