Level 2 Repair ( Driver Side and Passenger Side)
NOTE:The front strut removal procedure is the same on the driver side AND passenger side, unless stated otherwise.
Front Strut Removal
NOTE:
^ Use care during strut removal to prevent stress on electrical, hydraulic, and mechanical components.
^ If needed; spray the strut mounting bolts/nuts with Nissan Rust Penetrant (P/N 999MP-A3020P) or equivalent.
1. Support the transverse link (lower control arm) with a jack stand as shown.
a. Position the jack stand under the lower control arm.
b. Lower the vehicle until the lower control arm touches the jack stand.
NOTE:
Do not lower the vehicle beyond just touching the jack stand. Do not put tension on the coil spring.
2. Disconnect the following items:
^ Remove the clip and take the brake hydraulic line loose from its support.
^ Discard the clip, use a new clip for Brake line support reassembly.
^ Remove the bolt for the ABS sensor harness support.
^ Take the ABS sensor harness loose harness support from the support on the other side of strut (not shown).
^ Remove the lower strut bolts.
> Discard the nuts, use new ones for reassembly.
NOTE:
Do not remove the nuts from the stabilizer connecting rod.
3. Carefully separate the knuckle from the strut.
NOTE:
Do not let the knuckle fall away from the strut. This will cause the weight of the knuckle assembly to pull on the brake line and the driveshaft boot (if equipped).
4. Use an elastic strap or other suitable tool to secure the knuckle to the stabilizer bar as shown.
NOTE:
Make sure the knuckle assembly is secure. Its weight must be supported during the entire repair process.
5. Remove the 2 bolts for the ABS connector sensor connector cover.
6. Disconnect the ABS sensor connector.
The ABS sensor connector is on the back side of the cover.
7. Pull the ABS sensor harness from behind the strut.
8. Let the ABS sensor harness hang out of sensor the way as shown.
9. Raise the vehicle enough so the lower control arm is not touching the jack stand.
10. Remove the 3 upper strut mounting nuts.
Discard the nuts, use new ones for reassembly.
11. Maneuver the strut so it is hanging upside down as shown.
NOTE:
The weight of strut is supported by the stabilizer connecting rod.
Repair Bracket Installation for Driver Side AND Passenger Side Strut Housing
(Level 2 repair continued)
NOTE:
The repair bracket installation procedure is the same on both sides, unless stated otherwise.
WARNING:
Perform repairs in a well ventilated area.
NOTE:
For 4WD vehicles: If the driveshaft boot is ripped, it should be covered to prevent debris from entering the driveshaft joint.
1. Inspect the ABS sensor harness for damage. If damaged, repair as necessary.
2. Push the ABS harness and connector through the panel.
^ The harness/connector will now be sensor out of the working area.
3. Use a scraper bar to scrape off loose flaking rust and corrosion.
4. Clean all the loose rust from the strut housing and wheel house areas (see Figure RB3).
^ Use an abrasive pad or other suitable tool.
CAUTION:
Avoid contacting the brake line(s) with your abrasive tool.
NOTE:
If the brake line is in the way of an area that needs cleaning, move it out of the way by first removing the clip from the mount.
4a. Passenger side: work around the block best as possible (see Figure RB4).
NOTE:
Steps 5 and 6 apply to Driver Side only.
5. From under the hood, remove the air filter box and the air intake duct between the filter box and the engine.
6. Inspect the steering column upper joint for rub through (steering shaft) in the area circled in Figure RB5.
Check for rubbing/contact with the strut housing panel.
Contact may have occurred if the strut housing separated from the wheel house.
^ ONLY if the E-coat has been rubbed through to bare metal, the steering shaft will need to be replaced.
^ If the steering shaft needs replacement, you will be instructed to replace it later in this procedure.
7. Passenger side - as needed: Remove the battery, Relay box-2, etc, to access the strut tower for inspection of separation.
7a. Only if the strut housing panel is separated as shown in Figure RB6:
Use a wire brush to clean any loose rust, paint, or other debris from the area shown with dashed line.
8. Use low pressure compressed air to blow off dust and debris:
^ From the under hood side of the strut housing panel and the surrounding area, and
^ From the wheel house area.
9. Use isopropyl alcohol to clean/wipe down the area:
If the strut housing panel was separated, clean/wipe down the under hood side of the strut housing panel and the surrounding area.
^ Clean/wipe down the wheel house area.
10. Only if the strut housing panel is separated:
Completely and liberally coat the strut housing panel (in the area shown with dashed line) with self etching primer.
^ Use DuPont Etch Primer (P/N A-4119S) or equivalent.
^ Follow all product instructions.
^ A second coat may be needed for heavy rust spots.
^ Let each coat dry for 5 minutes.
NOTE:
Refer to the Parts Information for additional product details.
11. Completely and liberally coat the strut housing and wheel house area with self etching primer.
^ Use DuPont Etch Primer (P/N A-4119S) or equivalent.
^ Follow all product instructions.
^ Coat all of the exposed metal areas on the strut housing and wheel house panels.
^ A second coat may be needed for heavy rust spots.
^ Let each coat dry for 5 minutes.
NOTE:
Refer to the Parts Information for additional product details.
12. Driver side: Locate the 2 existing holes at the upper area of the strut housing panel (see Figure RB8a).
^ With a drill bit, enlarge the 2 existing holes to 10 mm (3/8 in).
13. Passenger side: Locate the one existing hole at the upper area of the strut housing panel (see Figure RB8a).
^ With a drill bit, enlarge the one existing hole to 10 mm (3/8 in).
14. Attach the repair bracket using the existing holes that you enlarged (see RB9).
^ The repair bracket is part of the Repair Kit listed in the Parts Information.
^ Use bolts and hex nuts from the Repair Kit.
^ Also use the existing bolt(s) where shown in RB9.
^ Tighten the bolts/nuts finger tight.
15. Only if the strut housing panel is separated:
a. Attach the ratchet strap as shown in Figure RB10.
b. Use the ratchet strap to pull the strut housing panel down until the existing threaded hole(s) is aligned with the matching hole in the repair bracket (see Figure RB10).
16. Install all bolts as shown in Figure RB10, and make them finger tight.
17. Align the bottom edge of the repair bracket with the edge of the body frame.
The bracket will have some movement in all directions. Move it (align it) the best possible.
18. Once the bottom edge is aligned, securely tighten all bolts (see Figure RB10).
^ At this time, a pair of locking pliers or equivalent tool may be used to further support the repair bracket (see Figure RB10).
^ Bolts need to be tight enough to hold the bracket in place while center punching and drilling holes in the next step.
NOTE:
Photos for installation of the repair bracket show the ratchet strap being used.
In most cases, the strut housing panel will not be separated and the ratchet strap will not be needed.
19. Drill the holes shown by white arrows in Figure RB11 to 10 mm (3/8 in):
a. Center punch the holes.
b. Pilot drill with a 1/8 drill bit.
c. Drill holes to 10 mm (3/8 in).
20. Passenger side: Draw a white line as shown in RB11.
21. When drilling is done, remove the repair bracket.
22. For the 4 holes that will have Rivet Nuts installed, drill final hole size to 13.1 mm (33/64 in). See Figure RB12.
NOTE:
Each dealer was shipped, at no charge, one 33/64 drill bit (J-50878).
23. Install Rivet Nuts in the 13.1 mm (33/64 in) holes.
^ Refer to Rivet Nut Installation.
CAUTION:
DO NOT use power tools or impact tools with the Rivet Tool - use hand tools only.
IMPORTANT:
^ Lower holes - Required: Rivet Nuts are required in the lower holes (indicated with dashed line in Figure RB12).
If the metal in the area of the lower holes will not support the rivet nuts, then the vehicle is "not repairable": Retain the vehicle at the dealer, supply the customer with a rental car, and Fax a completed Non-Repairable Report to Morley.
NOTE:
Upper holes - not required: If the metal in the area of the upper holes will not support rivet nuts, continue with the repair. Rivet nuts are preferred but not required in the upper holes.
Rivet Nut Installation Instructions
CAUTION:
DO NOT use power tools or impact tools with the Rivet Tool - use hand tools only.
NOTE:
Rivet Tool J-50835 comes with extreme pressure lubricant. Apply to the threads and contact points of part # 2 and part # 3 for approximately every 60 rivet nuts installed (enough for 15 brackets).
1. Thread no more than finger tight part # 2 into part # 3 until it bottoms out (see Figure RB14).
^ This is a left handed thread.
2. Insert part # 1 through part # 2 and part # 3 (see Figure RB15).
3. Thread a rivet nut onto part # 1 until it bottoms out no more than finger tight (see Figure RB16).
4. Insert the rivet nut into the 13.1 mm (33/64 in) hole until it bottoms out on its collar.
5. Install the rivet by performing the following:
a. Hold the rivet nut and tool against the body panel with moderate pressure.
b. Hold stationary part # 3 while turning part # 2 clockwise.
c. Turn part # 2 approximately 2 turns or until turning resistance increases.
^ At this point, the rivet nut is installed.
d. Un-thread part #1 from the rivet nut.
e. Perform steps 1 - 5d to install the remaining 3 rivet nuts.
24. Reinstall the ABS sensor harness in its harness & hole.
^ Make sure the rubber grommet is in place.
25. Prepare for application of LORD Fusor(R) 108B (P/N 999MP - 108BP) structural adhesive (see Figure RB21 and RB22).
a. Load cartridge of Fusor(R) 108B into the 2:1 dispensing gun.
b. Remove the cartridge cap and plugs (if this is the second use, remove the old nozzle).
c. Dispense/expel some material to make sure any hardened material is removed.
d. Install anew mixing nozzle onto the cartridge.
^ Make sure the nozzle retainer is installed (see Figure RB21).
NOTE:
^ Mixing nozzles are one-time use only. Do not reuse mixing nozzles.
^ Two mixing nozzles are included with each cartridge of Fusor(R) 108B.
^ Refer to the Parts Information for additional product details.
^ For cleanliness, using rubber gloves is recommended.
e. Dispense 2 beads of Fusor(R) 108B onto a paper that will be discarded.
^ Each bead should be about inch diameter and about 6 inches long (length of the nozzle).
NOTE:
Performing this action will ensure the dispenser plungers have leveled, air bubbles have been expelled, and adhesive is mixed correctly.
26. Liberally apply Fusor 108B to the back side of the repair bracket as shown.
^ The adhesive bead should be about inch diameter in all the areas shown.
NOTE:
Filling the two channels with 3 beads will ensure good adhesion in the channel area.
^ It is recommended to install one repair bracket at a time after applying Fusor 108B.
NOTE:
^ Each cartridge of Fusor 108B has enough material to install two repair brackets.
^ Leave the nozzle attached to the cartridge between applications. The nozzle will keep the cartridge sealed until the next use.
27. Passenger side: Liberally apply Fusor 108B on the strut housing area within the white line drawn earlier (see page 25, step 20, and Figure RB24).
28. Bolt the repair bracket into place.
^ Driver side: make sure the ABS harness is pulled through its hole in the repair bracket.
^ Use the correct nuts (see Figure RB25, or RB26 as it applies).
^ Do not use air tools to tighten the bolts.
^ Torque all new bolts/nuts to 50 Nm (5.1 kg-m,37 ft-lb).
^ Secure all existing bolts.
28a. Make sure adhesive is cleaned from the existing threaded hole(s).
^ Driver side, see Figure RB25.
^ Passenger side, see Figure RB26.
NOTE:
These holes are used to mount the ABS sensor connector cover.
29. If the ratchet strap was used, carefully remove it.
30. Clean excess adhesive from around the edges of the repair bracket.
NOTE:
See Additional Bolt Installation Information.
Additional Bolt Installation Information
Bolts that are preferred but not required (see Figure RB27):
If these bolts do not have enough metal to support them (make them tight), use Lord Fusor(R) 108B to glue the bolts in the holes. Do not leave open holes.
^ These bolts are preferred for bracket support, but not required.
Bolts with rivet nuts that Must accept the torque (see Figure RB27):
^ These bolts are required and must accept the torque value of 50 Nm (5.1 kg-m, 37 ft-lb).
^ If these bolts will not accept the specified torque value, the vehicle is not repairable:
a. Retain the vehicle at the dealer.
b. Supply the customer with a rental car.
c. Fax a completed Non-Repairable Report to Morley.
31. Inspect the metal brake lines under the hood and in the wheel house areas for damage due to contact with the separated strut housing.
^ If there is damage, replace the line(s).
^ Refer to the appropriate Service Manual for related brake line replacement information.
32. Driver side: Inspect the brake master cylinder for damage due to contact with the separated strut housing.
Contact with the strut housing may have occurred if the strut housing separated from the wheel house.
^ If there is damage, replace the master cylinder.
^ Refer to the appropriate Service Manual for brake master cylinder replacement information.
Patching Perforated Areas
(Level 2 repair, driver side AND passenger side - continued)
NOTE:
The Photo in Figure RB29 is an example of possible perforation. The vehicle you are working on may have perforation in additional areas, areas different than these, or may not have any perforation.
If the vehicle you are working on does not have perforation, skip to step 36.
33. Cut fiberglass cloth to cover perforated areas (see example in Figure RB29).
^ Cut cloth to cover at least 1 inch beyond the perforation on all sides, except when the perforation is next to the repair bracket.
^ Where perforation is next to the repair bracket, cut cloth to fit along the edge of the repair bracket.
^ If there is more then one perforation, cut fiberglass cloth for each perforated area.
^ Use 3M(TM) Bondo Fiberglass Repair Kit (P/N 422) or equivalent.
^ Use protective gloves (such as rubber gloves or disposable gloves) while working with fiberglass and resin.
^ Do not install fiberglass patch on or over the repair bracket.
34. Apply fiberglass patch to perforated areas.
^ No additional surface preparation is needed.
> Apply patch over the self etching primer.
> Cleaning/grinding to bare metal is not needed.
^ Use protective gloves (such as rubber gloves or disposable gloves) while working with fiberglass and resin.
^ Follow all warnings and cautions for the fiberglass product being used.
^ Follow the product instructions for applying the fiberglass patch
WARNING:
Perform repairs in a well ventilated area.
35. Allow the fiberglass patch and resin to harden before continuing (about 30 minutes).
36. Prepare for application of LORD Fusor(R) 800EZ (P/N 999MP - 9G000P) seam sealer.
a. Load the cartridge into a 1:1 dispensing gun (see Figure RB30).
b. Cut the tip at about inch diameter opening.
NOTE:
Refer to the Parts Information for additional product detail.
37. Apply Fusor 800EZ (seam sealer) as shown in Figure RB31.
^ Apply around the outer edges of the repair bracket. Make sure all gaps are filled.
^ Apply along the seams between the strut housing panel and the wheel house.
^ Use a brush or other suitable tool to smooth the sealer for good seam coverage.
^ Allow seam sealer to dry for 10-15 minutes.
^ Passenger side: Also apply seam sealer around the brake line junction block.
38. Driver side: Apply Butyl Sealer (P/N B6553 - 89915) around the opening for the ABS sensor harness (see Figure RB31).
39. Driver side OR passenger side: Only if strut housing panel is separated:
^ Apply Fusor(R) 800EZ (seam sealer) as shown in Figure RB32.
^ Apply along the front seam between the strut housing panel and the wheel house.
^ Use a brush or other suitable tool to smooth the sealer for good seam coverage.
^ Allow seam sealer to dry for 10-15 minutes.
40. Completely and liberally coat the area shown in Figure RB33 (strut housing and wheel house area) with rubberized undercoat.
^ Use 3M(TM) Rubberized Undercoating (P/N 051135 - 08883) or equivalent.
^ Follow all product instructions.
^ Coat all of the exposed metal areas on the strut housing and wheel house panels.
NOTE:
Refer to the Parts Information for additional product details.
41. Inspect the ABS sensor harness covering - if needed use electrical tape to wrap the harness.
42. Only if strut housing panel is separated:
Completely and liberally coat the area inside the dashed line shown in
Figure RB34 with self etching primer.
^ This is the under hood front of the strut housing panel.
^ Use DuPont Etch Primer (P/N A-4119S) or equivalent.
^ Follow all product instructions.
NOTE:
Refer to the Parts Information for additional product details.
43. Driver side: If the steering shaft needs replacement, replace it at this time.
^ Refer to steering shaft inspection, step 6.
^ Refer to Steering Shaft Replacement.
44. Driver side: Reinstall the air intake duct and the air filter box.
45. Reinstall the strut in reverse order of removal.
^ Use new nuts for the upper strut mount (P/N 01225 - 00231).
^ Nut torque is:
39-54 Nm (4.0 - 5.5 kg-m, 29-40 ft-lb)
^ Use new nuts for the lower strut mount (P/N 54588 - ED00A).
NOTE:
Reuse the original bolts.
^ Torque is:
151 - 165 Nm
(15.4 - 16.8 kg-m, 111 - 122 ft-lb)
^ Use a new clip for the brake line
mount (P/N 46206 - 2J00A).
^ Confirm the ABS sensor harness is mounted correctly as shown in Figure RB37.
^ Make sure the brake line is not not twisted
^ Use a new clip for the brake line mount (P/N 46206 - 2J00A).
^ Make sure the brake line is not twisted.
^ Confirm the ABS sensor harness is routed correctly behind the strut.
^ Make sure the ABS sensor harness is mounted correctly as shown in Figure RB38.
^ Make sure the ABS sensor harness connector cover is installed as shown.
> If the cover is missing, install a new one.
> Coat the cover with 3M Rubberized Undercoating (P/N 051135 - 08883); don't get any undercoat on the strut rod.
46. Reinstall the wheel.
^ Torque for wheel nuts is 118 - 147 Nm (12 - 15 kg-m, 87 - 108 ft-lb).
47. Check and adjust the front wheel toe.
NOTE:
Do not wash for 24 hours. This will allow time for the undercoat to completely cure before exposure to water.