Body - Repairing Loose Door Stops in A and B Posts
SECTION8
GROUP
81
NO.
808
DATE
Aug. 1996
Reparing door stops A- and B-posts
REFERENCE: TP 3239512, SECTION 8 (81, 84) BODY AND GLASS; 850 1992-
This service bulletin supersedes earlier SB 81-808 dated July 1996 which can be discarded. The templates have been corrected.
Repairing loose door stops in A- and B-posts
This Service Bulletin describes how to repair damaged door stop welds.
Door stop mountings are available as replacement parts if a mounting needs replacing.
P/N: Door stop mounting A-post 6817408-5
Door stop mounting B-post 6817409-3
WARNING!
The use of protective equipment such as safety goggles is recommended.
Procedures for preventing electronic component damage while are welding:
1. To avoid closed circuits remove the negative battery lead.
2. To avoid ground potentials for different control units, place the welding ground lead as close as possible to the welding spot.
3. If welding is to take place close to any control unit, one should remove the unit just to avoid the risk for heat damage.
Method, repairing door stop mounting in A-post
Preparations:
- Disconnect negative battery lead
- Remove front door
- Mask the A-post to protect it from welding and grinding damage
- Protect the interior of the car with a fireproof cover
Cut the existing mounting off the car.
Cut a section corresponding to the section of the mounting still on the car, from the new mounting (A). Grind the mounting clean and even so that the new mounting can be welded into place.
Warning!
The use of protective equipment as safety goggles is recommended when welding.
Tack weld the new mounting
Copy, cut out and use the template in this Service Bulletin to ensure the correct alignment.
Hold the template against the A-post, below the position of the mounting. Align the mounting above the illustration on the template.
Tack weld, check measurements and adjust if necessary.
Weld the mounting into place.
Weld any cracks in the A-post.
Grind the welds even
Steel brush and clean the surfaces to be sprayed Sand with tine emery paper.
Spray on primer, color coat and varnish. See Service Manual Section 8 (80) Paintwork Repairs
Treat repaired, unpainted surfaces with rustproofing agent
Use rustproofing agent.
Remove masking and protective cover
Reinstall front door.
Check and if necessary adjust its function.
Repairing door stop mounting in B-post
Preparations:
- Move the front seat as far forward as it will go and cover it with a fireproof cover.
- Protect carpets and upholstery on the rear seat with a fireproof cover
- Remove B-post panels.
- Disconnect battery negative lead.
- Disconnect connectors and remove wiring from the B-post.
- Remove rear door
Mask
Mask the B-post to protect it from welding and grinding damage
Mark the shaded section in the illustration using the template in this Service Bulletin.
Copy and cut out template.
Cut out the marked section
Use an electric saw with a short blade.
Stuff the hole in the B-post with a damp rag to protect against welding drops and residue. The rag should be large enough to be secured just under the round hole.
Clean around the damaged weld on the door stop mounting.
Use a rotary wire brush.
Replace the door stop mounting if it is damaged.
Align the door stop mounting
Use the template in this Service Bulletin. Position the template as illustrated. The door stop mounting should be above the marked section on the template.
Weld the door stop mounting.
Seam weld at "A" and "B".
Clean the weld and the surrounding area Use a rotary wire brush.
Remove the damp rag from the B-post
If necessary dry the damp area with compressed air.
Reinstall the removed panel section on the B-post.
Check that the fireproof cover is protecting the floor and interior trim.
Tack weld, align if necessary (use the template) and when the panel section is correctly positioned, seam weld the entire join.
Grind the welds even.
Take care not to damage interior trim.
Respray repaired surface Spray on primer, color coat and varnish. Dry with a heat lamp.
See Service Manual Section 8 (80) Paintwork Repairs
Rustproof
Spray the repaired inside and outside of the B-post with rustproofing agent.
Remove masking and protective cover
Reinstall wiring and panels.
Reinstall rear door.
Reconnect battery negative lead.
Check
Check door stop function and adjust if necessary.
WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01
Operation No. Labor description Time allowance
81392-2 Replacing door stop mounting on A-post 1.8 hr
81393-2 Replacing door stop mounting on B-post 1.9 hr