5-Door

Rear End Sheet Metal Repairs - 5-Door - Rear Bumper Mounting

Removal and Installation

Removal

- NOTE: The rear bumper mounting is manufactured from mild steel.







1. In this procedure, to make sure the vehicle is correctly aligned, it must be placed on an approved alignment jig.
2. The rear bumper mounting is replaced in conjunction with:
1. Rear bumper cover
2. Rear bumper
3. Back panel

3. For additional information relating to this repair procedure please see the following:
Refer to Service Precautions
Corrosion Protection
Body Dimensions
Standard Workshop Tolerances

4. Remove the back panel.
refer to: Back Panel.







5. Drill out the spot welds.
6. Separate the joints and remove the old panel.

Installation

1. Prepare the old and new panel joint surfaces.

2. NOTE: With panel in position check for access to spot weld the joints.

Offer up the new panel and clamp into position. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.

3. Remove the new panel.







4. NOTE: The graphic shows all joints, only drill for MIG plug welds where there is no access to spot weld.

Drill holes in new panel ready for MIG plug welding.

5. Deburr MIG plug locations in new panel.
6. Offer up the new panel and clamp into position. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.







7. NOTE: MIG plug welds can be substituted for spot welds if access is insufficient.

Spot weld and MIG plug weld where required.

8. Dress all welds.
9. Apply a zinc rich primer to any bare metal surfaces at this stage.

10. NOTE: Make sure all underbody joints are sealed following this repair procedure

The installation of associated panels and mechanical components is the reverse of removal.