Replacement

Replacement

1. Remove the related parts.

• Rear seat
• Trim and other luggage compartment fittings
• Left and right rear suspension assembly
• Handbrake parts
• Exhaust system
• Wire harness
• Other parts as necessary
• Fuel tank and fuel pipes

WARNING: Do not smoke while working near the fuel system. Keep open flames away from the fuel system. If necessary, remove the fuel tank and/or lines before welding nearby.

2. Pull out and straighten the damaged area.

• Check whether the damage extended to the rear floor cross member, rear inner wing and the passenger compartment, and pull out the damaged parts using the frame corrector.
• Impact damage to the rear floor spreads to related parts such as the rear frame, rear floor cross member and rear inner wing.
• Therefore, pull out the damaged areas with the frame straightener and measure in reference to body dimensional drawing.

NOTE: Use of a positioning jig is recommended.

A. Positioning Jig

3. Peel off the undercoat.

Heat the undercoat at the weld areas of the lower rear floor with a gas torch. Peel off the undercoat with a metal spatula.

CAUTION: Be careful not to burn the fittings inside the luggage compartment when heating.

4. Cut and prise off the rear panel.
5. Cut and prise off the rear floor.

• Cut off the rear floor with a gas cutter or air chisel. Level the spot welded flanges of the rear side frame and rear floor cross member, as shown by the bold line in the figure below.

NOTE: Cut the rear floor 15 mm (0.6 in from the welded flange of the rear floor cross member.