Freelander Service Procedures
CORROSION PREVENTION AND SEALING
77-4-10 SEALING
Underbody protection repairs
Whenever body repairs are carried out, ensure that full sealing and corrosion protection treatments are reinstated.
This applies both to the damaged areas and also to areas where protection has been indirectly impaired, as a result
either of accident damage or repair operations.
Remove corrosion protection from the damaged area before straightening or panel beating. This applies in particular
to panels coated with wax, PVC underbody sealer, sound deadening pads etc.
warn : DO NOT use oxy-acetylene gas equipment to remove corrosion prevention materials. Large volumes of fumes
and gases are liberated by these materials when they burn.
Equipment for the removal of tough anti-corrosion sealers offers varying degrees of speed and effectiveness. The
compressed air-operated scraper (NOT an air chisel) offers a relatively quiet mechanical method using an extremely
rapid reciprocating action. Move the operating end of the tool along the work surface to remove the material.
The most common method of removal is by means of a hot air blower with integral scraper.
High temperatures can be generated with this equipment which may cause fumes. Take care during its use.
Another tool, and one of the most efficient methods, is the rapid-cutting 'hot knife'. This tool uses a wide blade and is
quick and versatile, able to be used easily in profiled sections where access is otherwise difficult.
Use the following procedure when repairing underbody coatings:
1 Remove existing underbody coatings.
2 After panel repair, clean the affected area with a solvent wipe, and treat bare metal with an etch phosphate
material.
3 Re-prime the affected area.
caut: DO NOT, under any circumstances, apply underbody sealer directly to bare metal surfaces.
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Replace all heat-fusible plugs which have been disturbed. Where such plugs are not available use rubber
grommets of equivalent size, ensuring that they are embedded in sealer.
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Mask off all mounting faces from which mechanical components, hoses and pipe clips, have been removed.
Underbody sealer must be applied before such components are refitted.
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Brush sealer into all exposed seams.
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Spray the affected area with an approved service underbody sealer.
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Remove masking from component mounting faces, and touch-in where necessary. Allow adequate drying time
before applying underbody wax.
After refitting mechanical components, including hoses and pipes and other fixtures, mask off the brake discs and
apply a coat of approved underbody wax.
note : Where repairs include the application of finish paint coats in the areas requiring underbody wax, carry out paint
operations before applying wax.
STRUCTURAL ADHESIVES
Metal-to-metal adhesive is applied to critical joint areas during factory assembly. The material used is a high-
temperature, heat cured, nitrile phenolic which serves to bond two metal surfaces and also to seal the joint against
ingress of dust, moisture and fumes. This material is not suitable for service use and, during repair, should be
substituted by an approved Structural Adhesive.
Those joints which require the application of structural adhesive are detailed in the following Figures. Only joints
applicable to service panels are included. Apply structural adhesive where indicated or to the mating panel surface.
caut : When separating a joint treated with metal-to-metal adhesive, it is important to avoid distortion. Heat the joint
gradually until the bond weakens sufficiently to permit panel separation.
note : When spot welding through metal-to-metal adhesive, take particular care to adjust the transformer setting to
ensure a reliable weld.
