Mitsubishi Galant (2004+). Manual - part 37

BODY REPAIR

TSB Revision

BASE OF BODY REPAIR

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

TSB Revision

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

TSB Revision

BASE OF BODY REPAIR

9-29

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

TSB Revision

BASE OF BODY REPAIR

9-30

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)