Refitting

   Op. 7210E56 R.R. TAILGATE

- Ensure that the components connected are not distorted by checking the body alignment measurements with suitable equipment (reference rigs, templates or gauges).

- Straighten the body as necessary.

1. Using the jig saw, follow the cutting lines in the diagram.

- Use a rotary brush to remove the paint and gain access to the spot welds.

2. Use the chamfering machine to remove the spot welds shown in the diagram.

- Use the drill to chamfer the spot welds that are not accessible to the chamfering machine.

- Use a hammer and chisel to remove the previously chamfered spot welds.

- Remove the part from the vehicle.

- Straighten the edges of the vehicle using a hammer and dolly block.

- Remove the spot weld residues using a disc grinder.

- Use a rotary brush to clean the previously treated areas.

1. Apply electro-weldable paint.

Removing

1. Remove the anti-corrosion treatment from the entire perimeter of the inside and outside of the replacement part using a rotary brush.

2. Drill out the part at the indicated points.

- Apply electro-weldable paint to the edges involved.

1. Position the replacement part correctly on the vehicle and secure it using self-locking clamps.

- Check the alignment and the surrounding gaps.

2. Use the circular saw to cut the edges of the panel so that the join line is perfect.

- Remove the replacement part, the excess panels and the components used for the adjustment.

1. Position the replacement part correctly on the vehicle and secure it using self-locking clamps.

- Check the alignment and the surrounding gaps.

2. Use a spot welder to weld the areas shown in the diagram.

3. Apply a few tack welds in the upper area. Weld permanently when the roof is secured.

4. Use a MIG welder to fill weld the openings made previously.

5. Use a MIG welder to seam weld in the join areas.

- Correct any distortions to the panel using a hammer and dolly block.

1. Use a disc grinder to level the welds.

- Use a rotary brush to clean the previously welded areas.

1. Apply anti-oxidant protection to the areas involved in the welding.

- Seal the join lines between the replacement part and the vehicle.

    Op. 7210E28 R.R. ROOF PANEL