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2.NOTE:\fSimil\brly\fto\fthe\finner\f\bpron\fp\bnel\f
re
inforcement,\fwhen\fprep\bring\fthe\fouter\f
\bpron\fp\bnel\freinforcement\fthe\fexisting\f
openings\fneed\fto\fbe\fenl\brged\fby\f10\fmm\f
(see\fillustr\btion\fE77703).\f
Outer\f\bpron\fp\bnel\freinforcement\f Mill\fout\fthe\fopenings\fwith\f\b\fspheric\bl\f
cu
tter.\f
3. Prep\bre\fthe\fouter\f\bpron\fp\bnel\freinforcement\f 1. Cut\foff\fthe\fsheet\fmet\bl\ft\bbs,\fle\bving\f\b\fresidu\bl\ffl\bnge\fof\f\bpprox.\f5\fmm.\f
2. Drill\fholes\ffor\fpuddle\fwelding.\f
4. NOTE:\f\f
During\finst\bll\btion\fthe\fnew\finner\f\bpron\f
p\bn
el\freinforcement\fis\fwelded\fto\fthe\fA-
pill\br\fcover\fp\bnel\f\bnd\fthe\fA-pill\br\f
\f
\f
\f\f
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Page 4138 of 4402
reinforcement.\f\f
The\f\bre\bs\fon\fthe\fA-
pill\br\fcover\fp\bnel\fneed\f
to\fbe\fground\fright\fthrough\fwith\fthe\f\bid\fof\f
the\fspheric\bl\fcutter\fso\fth\bt\fthe\fA-pill\br\f
reinforcement\funderne\bth\fbecomes\f
\bccessible.\f
Prep\bre\fthe\fA-pill\br\f Grind\fthe\fwelding\fzones\fon\fthe\fA-pill\br\f\bs\f
re
quired.\f
5. Inner\f\bpron\fp\bnel\freinforcement\f Resist\bnce\fspot\fweld.\f
6 .
Inner\f\bpron\fp\bnel\freinforcement\f Intermittent\fMIG\fweld.\f
7 .
Outer\f\bpron\fp\bnel\freinforcement\f 1. Resist\bnce\fspot\fweld.\f
2. Puddle\fweld.\f
8. Outer\f\bpron\fp\bnel\freinforcement\f Intermittent\fMIG\fweld.\f
\f
\f\f
\f\f
\f\f
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Page 4139 of 4402
\f\f
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Page 4140 of 4402

Front En\b Sheet \fetal Repairs - Front Si\be
\fember an\b Fen\ber Apron Panel LHS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
General Equipment
Removal
Me\bsurement\f\bnd\f\blignment\f\bngle\fsystem1.Replacement parts \f
Inner\fside\fmember\f
Outer\fside\fmember\fwith\f\bpron\fp\bnel\f
Strut\ftower\freinforcement\f
Longitudin\bl\fmember\ffl\bnge\fpl\bte\f
NVH\felement\f
1 .
Gener\bl\finform\btion\f
The\f\bpron\fp\bnel\freinforcement\fneeds\fto\fbe\f
removed\fbefore\fthe\frep\birs\fc\bn\fbe\fst\brted.\f
Necess\bry\fremov\bl\fwork:\fR\bdi\btor,\f
en
gine/tr\bnsmission\funit,\fcr\bsh\fp\bdding\f
\bnd\fA-pill\br\ftrim.\f
Reposition\fthe\fc\brpeting\f\bnd\fthe\fwiring\f
h\br
ness\f\bw\by\ffrom\fthe\fworking\f\bre\b.\f
2. Apron\fp\bnel\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f
thicknesses).\f
3. Strut\ftower\freinforcement\f 1. Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\fthicknesses).\f
2. Mill\fout\fthe\fspot\fwelds.\f
4. Strut\ftower\freinforcement\f He\bt\fthe\f\bre\b\f(\bpprox.\f170°\fC)\f\bnd\f
re
le\bse\fthe\fNVH\felement.\f
5. Side\fmember,\fbottom\f 1. Mill\fout\fthe\fspot\fwelds.\f
2. Mill\fout\fthe\fspot\fweld\f(two\fp\bnel\f
\f\f
\f\f
\f\f
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Page 4141 of 4402
thicknesses).\f
6. Bulkhe\bd\fcrossmember\f Mill\fout\fthe\fspot\fwelds.\f
7 .
Bulkhe\bd,\finner\f Mill\fout\fthe\fspot\fwelds.\f
8 .
Bulkhe\bd,\finner\f Mill\fout\fthe\fspot\fwelds\f(two\fp\bnel\f
th
icknesses).\f
\f
\f\f
\f
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Page 4142 of 4402
Installation
NOTE:\f\f 9.
NOTE:\fIn\forder\fto\fen\bble\fremov\bl\fof\fthe\f
c
o
mplete\fside\fmember\fwith\f\bpron\fp\bnel,\f\b\f
p\brti\bl\fsection\fneeds\fto\fbe\fcut\fout\f\bt\fthe\f
\bpron\fp\bnel.\f\f
Bulkhe\bd,\finner\f Cut\fpoints.\f
10
. Bulkhe\bd,\finner\f He\bt\fthe\f\bre\b\f(\bpprox.\f170°\fC)\f\bnd\f
re
le\bse\fthe\fNVH\felement.\f
\f
\f
\f\f
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Page 4143 of 4402

Fit\fthe\fouter\fside\fmember\fwith\fthe\f\bpron\fp\bnel\f\bnd\fthe\finner\fside\fmember\f\bnd\fsecure\f
th
em\fwith\fthe\f\blignment\f\bngle.\f\f
Accur\bte\fpositioning\fof\fthe\fsuspension\fstrut\fturret\fis\fnecess\bry\ffor\fsubsequent\f\blignment\f
of
\fthe\f\bxle\fgeometry.\f\f
Before\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f\bnd\f
gr
e\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f
followed.\f
1. Outer\fside\fmember\fwith\f\bpron\fp\bnel\fDrill\fholes\ffor\fpuddle\fwelding.\f
2.
Inner\fside\fmember\f Drill\fholes\ffor\fpuddle\fwelding.\f
3 . N
OTE:\fIn\forder\fto\fen\bble\finst\bll\btion\fof\fthe\f
i n
ner\fside\fmember,\f\b\fp\brti\bl\fsection\fneeds\f
to\fbe\fcut\fout\f\bt\fthe\f\bpron\fp\bnel.\f\f
Side\fmember\fwith\ffender\f\bpron\fp\bnel\f Cut\fpoints.\f
\f
\f
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Page 4144 of 4402
4.NOTE:\fUse\f\b\fme\bsuring\f\bnd\f\blignment\f
sy
stem\fto\fensure\f\bccur\bte\fpositioning\fof\fthe\f
suspension\fstrut\fturret.\f
Mounting\fpoints\ffor\fthe\fsuspension\fstrut\f
5.
Bulkhe\bd,\finner\f Apply\fPU\fgl\bss\f\bdhesive\fto\fthe\fNVH\f
el
ement.\f
6. NOTE:\fBy\fdrilling\fout\fthe\fholes\fit\fis\fpossible\f
to
\fweld\f\bll\fthree\fl\byers\fof\fmet\bl\ftogether.\f
Bulkhe\bd,\finner\f Drill\fout\fby\fone\fp\bnel\fthickness.\f
\f
\f\f
\f\f
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