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Box Corner > < Rear Outer Wheelhouse Half

Transit 2006.5 (04.2006-)

Rear End Sheet Metal Repairs - Box Corner Section Transit 2006.5 (04/2006-)
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. NOTE:
    NOTE:The upper rough separating cut must be made exactly 100 mm above the rear lamp aperture. In doing so, make sure that the reinforcement panels behind are not damaged.
    Box corner outer panel
    • Rough separating cut.

  1. NOTE:
    NOTE:To remove the box corner, a part of the neighbouring side panel must be removed.
    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.

Installation
  1. Prepare the neighbouring side panel
    • Drill out the spot welds (2 panel thicknesses) and remove the flange remainder.

  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. Box corner
    • Align the box corner and secure it. Produce a continuous MIG weld seam with gaps.

  1. Neighbouring side panel
    • 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. Continuous MIG weld with gaps.

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

  1. Box corner
    • Puddle weld.

  1. Box corner (see from wheelhouse)
    • Puddle weld (two panel thicknesses).

Box Corner > < Rear Outer Wheelhouse Half