Repair Procedure

This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole.

1. Raise vehicle to gain access to the crossmember bolt.

2. Remove the crossmember bolt.

3. Lower the vehicle and open the door.

4. Slide the seat to the full rearward position. Remove the floor mat if so equipped.

5. Remove the scuff plate and kick panel.

6. Pull the carpet and pad away to access the floor.

7. Prop the clutch and brake pedal to make room for drilling (drivers side only).





8. Insert the template, mark and center punch the floor pan (Figure 1).

9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut.

10. Pry up on the cage surrounding the nut and slide the nut out.

11. Insert the new nut and bend the cage back into position to secure the nut.

12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.)

13. Lower the vehicle and vacuum all drill shavings.

14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor.





15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal.

16. Position pad and carpet into proper location.

17. Remove prop holding brake and clutch pedal if applied.

18. Install the scuff plate and kick panel.

19. Install floor mat and reposition seat.

20. Repeat procedure for other side if needed.