Range Rover Classic
76
CHASSIS AND BODY
4
REPAIR
BODY
Introduction:
The information which follows is concerned solely with
the ’Monocoque’ assembly of the inner body shell on
Range Rover models.
Body repairs often require the removal of mechanical
and electrical units and associated wiring. Where
necessary, reference should be made to the relevant
section of the Repair Manual for removal and refitting
instructions.
The inner body shell is of ’Monocoque’ construction
and to gain access to the repair area, it may be
necessary to remove exterior body panels, all exterior
body panels are bolted to the inner body shell to
facilitate easier panel removal and replacement or
repair.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the car to a safe running
condition and effecting a repair which is visually
acceptable.
WARNING: After collision damage has
been repaired and the airbags(s) has not
deployed, the SRS integrity must be
confirmed using TestBook.
WELDING
The following charts and illustrations show the
locations and types of weld for securing the body side
assembly, tailgate frame assembly and the front
valance and wheel arch assembly. Before undertaking
any spot weld joints to the inner body, it is advisable
to make a test joint using offcuts of the damaged
components, and to use this test piece to perform a
weld integrity test.
Spot welding is satisfactory if the joints do not pull
apart. If the weld pulls a hole or tears the metal the
weld is satisfactory. It is defective if the weld joint pulls
apart or if there are signs of burning, porosity or
cracking evident.
PREPARATION
Thoroughly clean all areas to be welded, remove any
sealants and corrosion protectives from around
original panels. Align and clamp all new panels in
position and check relationship to one another.