Replacement (page 3 of 4)

8. Set the repair part.

• Cut the repair part (new rear floor) to align it with the body.

NOTE: Cut the repair part so it overlaps the body side floor by approximately 40 mm (1.6 in).

• Remove the undercoat from both sides of the areas to be welded with a sander to expose the steel plate.

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

A. Repair Part

9. Set the new rear frame B and the repair part. Check the position of the rear frame A and new rear frame B and the repair part using the body dimensional drawings and the positioning jig.
10. Perform the main welding.

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

NOTE: Apply the spot sealer to the welding surface when spot welding

Spot welding: Remove the repair part, and weld the rear frame A and the new frame B securely. Recheck the position of the rear frames and repair part, then weld the repair part and rear frames.

• Make 20% to 30% more spot welds than there were holes drilled.

MIG welding:

• Drill the plug holes for welding the new rear frame B.
• Clamp the new rear frame B and repair part. Check the rear frame position, and weld the rear frame A and new rear frame B by means of the MIG welding. Weld the repair part to the rear frames.
• Weld the overlap of the rear floor by MIG welding.