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Rear Side Member Section > < Box Corner

Transit 2006.5 (04.2006-)

Rear End Sheet Metal Repairs - Back Panel and Crossmember Transit 2006.5 (04/2006-)
Removal and Installation

Materials
Name
Specification
Rear panel with cross member
 

Removal

  1. General notes
    • Necessary removal work: Rear doors, whole bumper

  1. Rear panel with cross member
    1. Mill out the spot welds (on both sides).
    1. Rough separating cut (one panel thickness).

  1. Rear side member
    • Mill out the spot welds (on both sides).

  1. Rear panel with cross member
    1. Mill out the spot welds (on both sides).
    1. Bend up the flange (on both sides).

  1. Rear panel with cross member
    • Mill out the spot welds (on both sides).

  1. Rear panel with cross member
    1. Rough separating cut.
    1. Rough separating cut (on both sides).

  1. NOTE:
    NOTE:The cut shown at one corner pillar is necessary to take out the complete old part and to install the new part. The part cut away will then be used again.
    Rear panel with cross member
    1. Rough separating cut.
    1. Swing out the old part and remove it.

Installation
  1. Prepare the new part
    1. Make holes for puddle welding. Copy from the old part if needed (on both sides).
    1. Rough separating cut. Bend up the flange by 90 degrees.

  1. Prepare the new part
    • Make holes for puddle welding (on both sides).

  1. Corner pillar remnant part
    • Mill out the spot welds and remove the flange remnants.

  1. Prepare the new part
    • Bring the corner pillar remnant part into the new part. DO NOT WELD.

  1. Rear panel with cross member
    1. Bring in at the left-hand corner pillar.
    1. Swing into final position, align and secure.

  1. Corner pillar remnant part
    • Align the corner pillar remnant part and continuous MIG weld.

  1. Rear panel with cross member
    • Continuous MIG seam weld.
  1. Align the rear panel with the cross member again.

  1. Rear panel with cross member
    1. Position the flange.
    1. Puddle weld (on both sides).
    1. Continuous MIG seam weld.

  1. Rear panel with cross member
    1. Puddle weld (on both sides).
    1. Puddle weld the hidden spot welds (on both sides).

  1. Rear panel with cross member
    1. Position the flange and puddle weld (on both sides).
    1. Puddle weld (on both sides).

  1. Rear side member
    • Puddle weld (on both sides).

Rear Side Member Section > < Box Corner