Frelander 2. Manual - part 658

 

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Frelander 2. Manual - part 658

 

 

Side Panel Sheet Metal Repairs - Rocker Panel

Removal and Installation

Removal

CAUTION: The rocker panel must be MIG slot brazed to the rocker panel inner reinforcement, which is DP600, (Dual

Phase steel). MIG plug welds / spot welds must not be used.

• NOTE: The rocker panel is serviced as a separate weld-on panel.

1. The rocker panel is replaced in conjunction with:

Front bumper cover

Front fender

Front door

Rear door

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 fender.
4. Remove the front door.

For additional information, refer to: 

Front Door

 (501-03 Body

Closures, Removal and Installation).

5. Remove the rear door.

For additional information, refer to: 

Rear Door

 (501-03 Body

Closures, Removal and Installation).

6. Remove the front road wheel.

For additional information, refer to: 

Wheel and Tire

 (204-04

Wheels and Tires, Removal and Installation).

7. Remove the rear road wheel.

For additional information, refer to: 

Wheel and Tire

 (204-04

Wheels and Tires, Removal and Installation).

8. LH side: Remove the hood release handle.
9. Remove the front seat.

For additional information, refer to: 

Front Seat

 (501-10

Seating, Removal and Installation).

10. Remove the floor console.

For additional information, refer to: 

Floor Console

 (501-12

Instrument Panel and Console, Removal and Installation).

11. Remove the front door aperture weatherseal.
12. Remove the rear door aperture weatherseal.
13. Remove the cowl side trim panel.

For additional information, refer to: 

Cowl Side Trim Panel

(501-05 Interior Trim and Ornamentation, Removal and

Installation).

14. Remove the B-Pillar upper trim.

For additional information, refer to: 

B-Pillar Upper Trim Panel

(501-05 Interior Trim and Ornamentation, Removal and

Installation).

15. Remove the RH & LH B-Pillar lower trims.

For additional information, refer to: 

B-Pillar Lower Trim Panel

(501-05 Interior Trim and Ornamentation, Removal and

Installation).

16. Remove the rear quarter trim panel.

For additional information, refer to: 

Rear Quarter Trim Panel

(501-05 Interior Trim and Ornamentation, Removal and

Installation).

17. Remove the RH & LH rocker panel inner trims.
18. Remove the rocker panel outer moulding.
19. Remove the back panel inner trim.
20. Remove the rear seat cushion.

For additional information, refer to: 

Rear Seat Cushion

 (501-10

Seating, Removal and Installation).

21. Remove the front safety belt retractor.

For additional information, refer to: 

Front Safety Belt Retractor

(501-20A Safety Belt System, Removal and Installation).

22. Remove the rear carpet section.
23. Release and lay aside the front carpet section.
24. Remove the B-Pillar side impact sensor.

For additional information, refer to: 

B-Pillar Side Impact Sensor

(501-20B Supplemental Restraint System, Removal and

Installation).

25. Remove the C-Pillar side impact sensor.

For additional information, refer to: 

C-Pillar Side Impact Sensor

(501-20B Supplemental Restraint System, Removal and

Installation).

26. Release and lay aside the bulkhead inner insulation.
27. Release and lay aside the wiring harness along the inner

rocker panel.

28. Saw cut the old panel at its joints with the A-Pillar, B-Pillar

and quarter panel, ensuring there is an allowance for the

new panel to overlap. Use the new panel for reference.

29. Mill out the spot welds.

30. Separate the joints and remove the old panel.

Installation

1. Offer up and align the new panel and clamp into position,

overlapping the old panel remaining on the vehicle.

2. Saw cut through the new and old panels at the A-Pillar,

B-Pillar and quarter panel, where the MIG butt joints are to

be made.

3. Remove the new panel and the old remnants.

4. NOTE: MIG slots should be installed in accordance with the

spacing shown in the illustration. Where this is not possible,

due to the indents in the panel, the slot should be made in the

location of the original spot weld.

Cut slots in the new panel ready for MIG brazing.

5. Prepare the old and new panel joint surfaces.
6. Offer up the new panel and clamp into position. Check

alignment, if correct, proceed to next step, if not, rectify and

recheck before proceeding.

7. Tack weld the butt joints.

8. MIG braze the slots.

9. Dress the tack welds.

10. MIG weld the butt joints.

11. Dress all welded joints.

Rear End Sheet Metal Repairs - Rear End Sheet Metal

Description and Operation

Rear end service panels

Item

Description

1

Inner quarter panel front

2

Inner quarter panel rear

3

Inner quarter panel

4

Rear wheelhouse outer

5

Water drain panel section

6

Rear lamp mounting panel

7

Rear bumper cover

8

Rear bumper

9

Quarter panel

10

Back panel assembly

11

Back panel

12

Spare wheel well

13

Rear crossmember

14

Rear wheelhouse front extension

15

Rear side member closing panel

16

Rear side member upper side extension

17

Rear side member lower side extension

18

Rear side member section

 

 

 

 

 

 

 

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