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Rocker Outer Panel Reinforcement Replacement (Front)

Rocker Outer Panel Reinforcement Replacement (Front)

Removal Procedure

Refer to Approved Equipment for Collision Repair Warning .

Refer to Collision Sectioning Warning .

Refer to Glass and Sheet Metal Handling Warning .


1. Disable the SIR system. Refer to SIR Disabling and Enabling .

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

3. Visually inspect the damage. Repair as much of the damage as possible.

4. Remove the rocker panel (center). Refer to Rocker Panel Replacement (Rear) Rocker Panel Replacement (Front) Rocker Panel Replacement (Center) Rocker Panel Replacement (Complete) .

5. Remove the rocker panel (front). Refer to Rocker Panel Replacement (Rear) Rocker Panel Replacement (Front) Rocker Panel Replacement (Center) Rocker Panel Replacement (Complete) .

6.
Note

Do not damage any inner panels or reinforcements. Note the number and location of the welds for installations of the service part.


Create a cut line on the rocker outer panel reinforcement (front) in the area (1).


7. Locate and drill out all of the necessary factory welds on the rocker outer panel reinforcement (front) (2), (3).

8. Remove the damaged the rocker outer panel reinforcement (front) (1).



Installation Procedure


1. Prepare the new rocker outer panel reinforcement (front).


2. Cut (1) the new rocker outer panel reinforcement (front) in corresponding to the fit of the original panel. The sectioning joint should be trimmed to allow min. 1 times the metal thickness at the sectioning joint.

3. Prepare the body in the area (2).

4x slots 6 x 20 mm (0.2 x 0.8 in)

4. Prepare the body in the area (1).

1x slot 8 x 24 mm (0.3 x 0.9 in)


5. Prepare the body in the area (2).

5x slots 8 x 24 mm (0.3 x 0.9 in)

6.
Note

Refer SPP, PSO welding parameters for resistance spot welding. See TIS Newsletter for equipment recommendations.


Clean and prepare the attaching surfaces for welding.


7. Apply bodywork repair through structural adhesive to body (1). Refer to Structural Adhesive Body Repairs .

8. Position the new rocker outer panel reinforcement (front) (1) on the vehicle.


9. Verify the fit of the new rocker outer panel reinforcement (front) (1).

10. Clamp the new rocker outer panel reinforcement (front) (1) into position.

11.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


MIG-braze (1) the rocker outer panel reinforcement (front).


12. Spot weld (2) the rocker outer panel reinforcement (front) accordingly.

13. MIG-braze (3) the slots on the rocker outer panel reinforcement (front).

14. Grind MIG-brazed seams.

15. Cut out a 70 mm / 2.8 in (1) backing plate (2) from an unused area of the service part.


16. Drill fastening holes (3) for high strength rivets.

8 holes 6.8 mm / 0.28 in

17. Rivet the backing plate (3) on the rocker outer panel reinforcement (rear).

18. Cut out a 130 mm / 5.1 in (3) backing plate (1) from an unused area of the service part.


19. Drill fastening holes (2) for high strength rivets.

8 holes 6.8 mm / 0.28 in

20. Rivet the backing plate (2) on the rocker outer panel reinforcement (front).

21. Install the rocker panel (center). Refer to Rocker Panel Replacement (Rear) Rocker Panel Replacement (Front) Rocker Panel Replacement (Center) Rocker Panel Replacement (Complete) .

22. Install the rocker panel (front). Refer to Rocker Panel Replacement (Rear) Rocker Panel Replacement (Front) Rocker Panel Replacement (Center) Rocker Panel Replacement (Complete) .

23. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) Anti-Corrosion Treatment and Repair (Corrosion Protection) .

24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

25. Enable the SIR system. Refer to SIR Disabling and Enabling .