Rocker Outer Panel Sectioning (Complete)
Special Tools
• |
BO-6392
Flanging Tool Kit |
For equivalent regional tools, refer to
Special Tools .
Note: According to
different corrosion warranties, only the regional mandatory joining
methods are allowed.
Removal Procedure
3. |
Remove all related panels and
components. |
4. |
Visually inspect the damage.
Repair as much of the damage as possible. |
5. |
Remove the sealers and
anti-corrosion materials from the repair area, as necessary.
|
6. |
Create cut lines on the rocker
outer panel (1). |
|
Note: Do not damage
any inner panels or reinforcements.
|
7. |
Cut the rocker outer panel (1)
where sectioning is to be performed. |
8. |
Locate and mark all the
necessary factory welds of the rocker outer panel (1). |
9. |
Drill all factory
welds. |
10. |
Remove the damaged rocker
outer panel (1). |
Installation Procedure
1. |
Cut the rocker outer panel in
corresponding locations to fit the remaining original panel. The
sectioning joint should be trimmed to allow a gap of
one-and-one-half-times the metal thickness at the sectioning joint.
Create 5 x 5 x 18 mm slots (1) for MIG-brazing. |
2. |
Prepare all mating surfaces as
necessary. |
3. |
Align the rocker outer
panel. |
4. |
Clean and prepare the
attaching surfaces for spot welding. |
|
Note: In MIG-brazing
areas 50 mm (2 in) must be kept clear of structural adhesive.
|
5. |
Apply structural adhesive (1)
to the attaching surfaces. |
6. |
Position the rocker outer
panel (1) on the vehicle. |
7. |
Verify the fit of the rocker
outer panel. |
8. |
Clamp the rocker outer panel
into position. |
9. |
Spot weld the rocker outer
panel (1) accordingly. |
|
• |
Flange front side door opening
(2) - 20 spot welds |
|
• |
Flange rear side door opening
(3) - 17 spot welds |
|
• |
Rocker panel rear (4) - 3 spot
welds |
|
• |
Lower flange rocker panel (5)
- 34 spot welds |
10. |
Braze the rocker outer panel
(1) accordingly. |
|
• |
Rocker outer panel / body
hinge pillar (2) - 230 mm |
|
• |
Rocker outer panel / center
pillar (3) - 360 mm |
|
• |
Rocker outer panel / quarter
outer panel (4) - 320 mm |
|
• |
Rocker outer panel / 4 x 5 x
18 mm slot brazes (5) |
11. |
To create a solid braze with
minimum heat distortion, make 25 mm (1 in) stitch brazes along the
seam with 25 mm (1 in) gaps between them. Then go back and complete
the stitch braze. |
12. |
Pre-flanging the flange with
BO-6396 pliers and BO-6392 tool kit
. |
13. |
Finish closing the wheelhouse
flanging. |
14. |
Apply the sealers and
anti-corrosion materials to the repair area, as necessary.
|
15. |
Paint the repaired
area. |
16. |
Install all related panels and
components. |
|