Front wheel housing and front frame member
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Front wheel housing and front frame member
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1.
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Remove the door frame, see Section of door frame, three-door body; Door frame, three-door body or Section of door frame, five-door body.
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2.
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Position the car in an aligning bench and cross-measure if necessary.
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3.
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Position a door opening support between the floor and roof so that the roof does not sag when the wheel housing is removed.
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4.
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Cut the wheel housing so that the welding points are accessible with a spot-weld drill.
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5.
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Drill out the spot-welds and tap loose the remaining sections of the wheel housing.
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6.
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Cut the cross-member according to the markings shown on the illustration.
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Important
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The crossmember must only be joined according to the markings. If the damage extends beyond the marking, the entire crossmember must be replaced.
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7.
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Drill out the spot welds securing the cut section of frame member and crossmember. Drill through all the panels including the floor. Grind away the seam welds.
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8.
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Remove the cut sections of frame member and crossmember and align any sheet metal or panel damage.
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9.
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Drill holes in the body where the new frame member is to be welded.
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10.
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Grind clean the surfaces on the to be welded on the frame member and body.
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11.
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Remove grinding debris from the inside of the frame member, otherwise the risk for corrosion increases.
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12.
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Apply welding primer on the surfaces to be plug-welded. Use Teroson Zinkspray.
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13.
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Fit the frame member and secure it with a couple of welding clamps. Adjust the exact position using the aligning bench measuring system.
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14.
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Plug-weld and seam-weld on the frame member.
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15.
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Cut the crossmember and align it.
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16.
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Fit the crossmember and secure it with a couple of welding clamps.
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17.
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Remove the crossmember and drill holes for plug-welding in the crossmember.
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18.
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Grind clean the surfaces to be welded on the cross-member and the body.
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19.
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Apply welding primer on the surfaces to be plug-welded. Use Teroson Zinkspray.
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20.
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Fit the crossmember and secure it with a couple of welding clamps.
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21.
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Plug-weld the cross-member.
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22.
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All-weld the joint on the cross-member.
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23.
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Drill holes for plug-welding in the new wheel housing where it is not possible to reach with a spot-welder.
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24.
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Grind clean the surfaces to be welded on the body and in the new wheel housing.
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25.
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Apply welding primer on the surfaces to be plug and spot-welded on the wheel housing and on the body. Use Teroson Zinkspray.
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26.
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Fit the new wheel housing and secure with a few welding clamps.
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27.
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Measure in the wheel housing using the aligning bench measuring system.
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28.
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Fasten the wheel housing with a couple of welds.
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29.
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Fit the front wing and the bonnet, check the fit of the wheel housing.
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30.
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Remove the front wing and bonnet.
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31.
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Spot and plug-weld the housing into place.
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33.
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Grind clean the surfaces to be welded on the body and reinforcements that are to be fitted on the outside of the wheel housing.
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34.
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Apply welding primer on the surfaces to be spot-welded. Use Teroson Zinkspray.
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35.
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Weld on the reinforcement on the outside of the wheel housing.
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36.
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Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.
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37.
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Saab 9-3 Viggen:
The two lower bolts in the wheel housing behind the front wheel should be cut to give clearance for the wheel. Cut them to a maximum length of 10 -12 mm. Then use the nuts, part no. 47 41 203, when fitting the wing liner.
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38.
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Apply primer to all ground surfaces. Use Standox 1K Primer.
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39.
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Seal folds and panel edges with sealant. Use Terostat 1K-PUR.
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40.
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Apply underseal to the bottom of the frame and crossmember. Use Terostat 9320.
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41.
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Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400 or Mercasol 1.
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