Replacement (page 3 of 5)

• Keep the holes to a minimum since they will be used as weld holes for MIG welding of the new part.

7. Set the new rear support stiffener in the original position properly and place a jack under the rear support stiffener for support.

• Remove the undercoat from both sides of the welding section, and expose the steel plate using a disc sander.

WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

A. New Rear Support Stiffener

• Check the position of the rear support stiffener using the body dimensional drawing.
• Temporarily weld the mating surfaces with the dashboard lower and inside sill extension.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

8. Set the new front side outrigger.

• Remove the undercoat from both sides of the areas to be spot welded with a sander to expose the steel plate.
• Clamp the weld flanges with the side sill using the vice-grip pliers. Set the front side outrigger on the side frame using a jack.
• Drill 3 mm (0.12 in) holes, and screw 5 mm self-tapping screws into the drilled holes at the areas where the front side outrigger does not fit closely.

A. New Front Side Outrigger

• Recheck the position of the new front side frame and rear support stiffener.
• Remove the new front side outrigger.

9. Main weld the new rear support stiffener and inside sill extension.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

10. Tack weld the new front side outrigger.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

• Check the body dimensions.
• Install the rear beam, and check the front side outrigger position.