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Box Corner Section > < Rear Inner Wheelhouse Half

Transit 2000.5 (01.2000-05.2006)

Rear End Sheet Metal Repairs - Box Corner Transit 2000.5 (01/2000-05/2006)
Removal and Installation

Materials
Name
Specification
Box corner
 

Removal

  1. General notes
    • Necessary removal work: inner trim, rear lamp, rear door, bumper, bumper corner, rear cross member

  1. Box corner
    • Rough separating cut.

  1. NOTE:
    NOTE:The upper rough separating cut must be made approximately 10 mm below the drip rail. In doing so, make sure not to damage the drip rail.
    Box corner
    • Rough separating cut.

  1. Box corner
    1. Mill out the spot welds.
    1. Mill out the spot welds along the whole length of the flange.

  1. Neighbouring side panel
    1. Rough separating cut.
    1. Mill out the spot welds.

  1. Box corner outer panel and neighbouring side panel
    1. Bend the flange up and mill out the spot welds underneath.
    1. Mill out the spot welds (free the outer panel).
    1. Mill out the spot welds.

  1. Box corner
    • Mill out the spot welds.

  1. Box corner
    1. Mill out the spot welds.
    1. Rough separating cut (one panel thickness).

  1. Box corner
    • Mill out the spot welds.

  1. NOTE:
    NOTE:Depending on the extent of the damage and ease of access, after the following step the relevant reinforcements and gussets should be exposed.
    Box corner
    1. Bend up the flange by 90 degrees.
    1. Rough separating cut. Maintain a distance of 10 mm between the closing panel with cross member and the cut line. Do not damage the reinforcement located behind. Remove the old box corner.

  1. Box corner
    1. Drill out the spot welds (2 panel thicknesses).
    1. Drill out the spot welds (three panel thicknesses).
    1. Mill out the spot welds and remove the flange remnants.

  1. Box corner
    • Drill out the spot welds (2 panel thicknesses) and remove the flange remainder.

Installation
  1. Prepare the neighbouring side panel
    • Remove the flange remnant of the box corner outer panel along the whole length of the side panel. Make holes for puddle welding in the area marked.

  1. Prepare the new part
    1. Add the missing spot welds.
    1. Make holes for puddle welding.

  1. Prepare the new part
    • Add the missing spot welds.

  1. Prepare the new part
    • Add the missing spot welds.

  1. Prepare the new part
    • Add the missing spot weld.

  1. Prepare the new part
    • Drill through the drip rail closing panel (two panel thicknesses).

  1. Prepare the new part
    • Make holes for puddle welding.
  1. Align the box corner and secure it.

  1. Neighbouring side panel
    • Puddle weld.

  1. Box corner and neighbouring side panel
    • Intermittent MIG weld (bead length 5 mm, distance between each 30 mm).

  1. Box corner and neighbouring side panel
    • Hollow grind the intermittent MIG weld seam.

  1. Box corner
    • Puddle weld.

  1. Box corner
    • Puddle weld.

  1. Box corner and neighbouring side panel
    1. Puddle weld.
    1. Spot weld a backing strip in place.
    1. Lay the flange back down and puddle weld.

  1. Neighbouring side panel
    1. Puddle weld.
    1. Intermittent MIG weld with gaps.

  1. Box corner
    1. Puddle weld.
    1. Continuous MIG weld seam.

  1. Box corner
    • Puddle weld.

  1. Box corner
    • Puddle weld (two sheet metal layers).

Box Corner Section > < Rear Inner Wheelhouse Half