Page 2969 of 3039
10.
11. NOTE: Drill out from underneath to allow spot welds
to be used in installation. If undamaged, retain the
mounting bracket for re-use on installation.
If the left-hand rear floor side extension is to be repaired,
drill out the spot welds, from underneath and remove the
mounting bracket.
NOTE: Drill out from underneath to allow spot welds
to be used in installation. If undamaged, retain the AJB
(auxiliary junction box) mounting bracket for re-use on
installation.
If the right-hand rear floor side extension is to be repaired,
drill out the spot welds, from underneath and remove the
AJB mounting bracket. www.JagDocs.com
Page 2970 of 3039
Page 2971 of 3039
Page 2972 of 3039
12. If the right-hand rear floor side extension is to be repaired,
spot weld the AJB mounting bracket as indicated.
13. Dress all welded joints.
14. Make sure any remaining areas of bare metal created during this
procedure are treated with a zinc primer prior to the installation of outer
panels.
15. NOTE: Make sure all underbody joints are fully sealed following this
repair procedure.
The installation of associated panels and components is the reversal of
removal procedure.
Page 2973 of 3039
(100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
5. NOTE: This procedure assumes that if the rear side member closing
panel section is damaged, the rear side member section will also be
damaged. Therefore the replacement procedure for the rear side member
closing panel section is combined within the rear side member section
procedure.
Remove the rear side member section.
For additional information, refer to: Rear Side Member Section (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
Installation
1. The installation of associated panels and components is the reversal of
removal procedure.
Page 2974 of 3039

Rear End Sheet Metal Repairs - Rear Side Member Section
Removal and Installation
Removal Published: 11-May-2011
1. NOTE: The rear side member section is manufactured from
High Strength Low Alloy Steel, 350MPa, (HSLA350).
The rear side member section is cut from the rear side
member service panel.
2. This procedure assumes that if the rear side member section is
damaged, the rear side member closing panel section will also be
damaged. Therefore this procedure combines the repair of the rear side
member section and the rear side member closing panel section.
3. NOTE: The rear side member closing panel section is
manufactured from High Strength Low Alloy Steel, 350MPa,
(HSLA350).
The rear side member closing panel section is cut from the
rear side member closing panel service panel.
4. In this procedure, to make sure the vehicle is correctly aligned, it must
be placed on an approved alignment jig.
5. The rear side member section is replaced in conjunction with:
Rear bumper cover
Rear bumper
Luggage compartment lid
Back panel
Spare wheel well
Towing eye bracket
Rear floor side extension
Rear side member closing panel section
Rear subframe and rear suspension, as an assembly
6. For additional information relating to this repair procedure please see
the following:
For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) / www.JagDocs.com
Page 2975 of 3039

Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
7. Disconnect the generator electrical connectors.
8. Remove the luggage compartment lid.
For additional information, refer to: Luggage Compartment Lid (501-03 Body Closures, Removal and Installation).
9. Remove the spare wheel well.
For additional information, refer to: Spare W heel Well (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
10. Remove the rear floor side extension.
For additional information, refer to: Rear Floor Side Extension (501-30 Rear End Sheet Metal Repairs, Removal and Installation).
11. Remove the rear muffler hanger bracket from the side member.
12. NOTE: The measurements shown allow the section to
be performed, avoiding the inner reinforcements and
allowing for a minimum 50mm staggered joint with the rear
side member closing panel section. The measurement is
taken from the edge of the hole in the rear side member,
not the inner reinforcement.
Mark out the position where the rear side member section
MAG butt joint is to be made. Cut through the rear side
member at this point, also cutting through the rear side
member closing panel as indicated.
Page 2976 of 3039
13.
14. CAUTION: Care should be taken not to cut through
into the rear side member.
Mark out the position where the rear side member closing
panel section MAG butt joint is to be made. Cut through the
rear side member closing panel at this point as indicated.
Drill out the spot welds from the rear side member closing
panel remnant.
15. Separate the joints and remove the rear side member closing panel
remnant.