TD5 Defender
77
PANEL REPAIRS
2
PROCEDURES
PANEL REPLACEMENT PROCEDURE
General
This information is designed to explain the basic panel
removal and replacement method. This standard
method may vary slightly from one vehicle to another.
The main criterion in removal and replacement of
body panels is that Land Rover’s original standard is
maintained as far as possible.
All repair processes and procedures shown relate to
Aluminium panels.
Remove Panel
1. Expose resistance spot welds. For those spot
welds which are not obviously visible, use a
rotary drum sander or wire brush fitted to an air
drill, or alternatively a hand held wire brush.
WARNING: Ensure breathing mask and
protective glasses are worn during
operations where Aluminium particles are
removed.
CAUTION: Never use a sanding disc that
has previously been used on steel, as iron
deposits could be left on the surface of the
Aluminium.
NOTE: In wheel arch areas it may be
necessary to soften underbody coating
using a hot air gun, prior to exposing spot
welds.
2. Cut out welds using a cobalt drill.
3. Alternatively use a clamp-type spot weld
remover.
