Body Construction, Regular Cab Page 3A–1
Page 3A–1
Section 3A
Body Construction, Regular Cab
ATTENTION
Before performing any Service Operation or other procedure described in this Section, refer to Section 2
Precautions, and Section 00 Warnings, Cautions and Notes in the MY 2004 VY Regular Cab and Crew Cab
Service Information for correct w orkshop practices with regard to safety and/or property damage.
The body structure of VY Regular Cab and
Crew Cab vehicles has been developed using
complex design and d evelopment techniques.
In addition to meeting all required standards,
the vehicle body is also a critical part of the
overall safety systems. It is therefore
imperative the repair procedures described in
this Supplement are adhered to during all
vehicle body repairs.
1 General Information ...............................................................................................................................3
2 Body Structure Panels...........................................................................................................................4
2.1 Front End & Underbody ........................................................................................................................................ 5
2.2 Upperbody Structure............................................................................................................................................. 7
2.3 Body Assembly...................................................................................................................................................... 9
3 Body Dimensions.................................................................................................................................11
3.1 Underbody Dimensions – Projected .................................................................................................................. 11
3.2 Upperbody Dimensions – Actual........................................................................................................................ 14
Front...................................................................................................................................................................... 14
Side & Interior ...................................................................................................................................................... 15
4 Body Margins........................................................................................................................................16
5 Body Sealing, Adhesives & Deadeners .............................................................................................18
5.1 Description........................................................................................................................................................... 18
Weld Through Primer (Item 1)............................................................................................................................. 18
Acrylic Spot Weld Sealer (Item 2)....................................................................................................................... 18
Joint Sealer (Item 3)............................................................................................................................................. 18
Hand Putty (Item 4).............................................................................................................................................. 18
Adhesive - Anti-Flutter (Item 5)........................................................................................................................... 18
Adhesive - Structural (Item 6)............................................................................................................................. 18
Spray-on Deadener (Item 7) ................................................................................................................................ 18
Floor Deadener Panels........................................................................................................................................ 19
Commercially Available Sealer, Adhesive and Deadener Equivalents ........................................................... 19
5.2 Acrylic Spot Weld Sealer (Item 2)....................................................................................................................... 20
Acrylic Spot Weld Sealer (Item 2) Continued .................................................................................................... 21
Acrylic Spot Weld Sealer (Item 2) Continued .................................................................................................... 22
Acrylic Spot Weld Sealer (Item 2) Continued .................................................................................................... 23
Body Construction, Regular Cab Page 3A–2
Page 3A–2
5.3 Joint Sealer (Item 3)............................................................................................................................................. 24
Joint Sealer (Item 3) Continued.......................................................................................................................... 25
Joint Sealer (Item 3) Continued.......................................................................................................................... 26
Joint Sealer (Item 3) Continued.......................................................................................................................... 27
Joint Sealer (Item 3) Continued.......................................................................................................................... 28
Joint Sealer (Item 3) Continued & Hand Putty (Item 4)..................................................................................... 29
5.4 Adhesive – Anti-Flutter (Item 5).......................................................................................................................... 30
5.5 Adhesive – Structural (Item 6) ............................................................................................................................ 31
Adhesive – Structural (Item 6) Continued.......................................................................................................... 32
5.6 Spray-on Deadener.............................................................................................................................................. 33
5.7 Deadeners & Insulators....................................................................................................................................... 34
6 Cavity Wax ............................................................................................................................................36
Cavity Wax Equivalents....................................................................................................................................... 36
Body Construction, Regular Cab Page 3A–3
Page 3A–3
1 General Information
With the following exceptions VY Regu lar Cab body construction information carries over from MY 2003 VY Series
vehicles.
• Body structure panels
• Body dimensions
• Body margins
• Body sealing, adhesives and deadeners
• Cavity wax
For information not contained within this Section, refer to Section 3 Body Construction-, in the MY 2003 VY and V2
Series Service Information Supplement, Body Structure Repair.
This Section contains body construction information specific to VY Regular Cab vehicles, for VY Crew Cab Body
Construction information refer to Section 3B Body Construction, Crew Cab. Described is the body structure as a whole
and provided is a detailed breakdown of the body structure components, key body dimensional measurements and body
margin tolerances.
The various sealers and adhesives used throughout the body are also described, as it is imperative that only the correct
materials are used for repairs.
The correct cavity wax, deadeners a nd paint refinishing techniques are also imperative if the vehicle is to be returned to
its original condition. When re placing or repairing a part or sub-assembly, care must be taken to ensure that correct
alignment and strength of unit as a whole is maintained. In some instances, major damage to the body can be repaired
more effectively and economically by replacing a part or sub-assem bly with a new one, rather than repairing th e
damaged part.
Body Construction, Regular Cab Page 3A–4
Page 3A–4
2 Body Structure Panels
The following tables and illustrations describe the body structure assemblies and panels that are available for service
replacement.
NOTE
Always refer to an authorised dealer for spare
parts availability configurations.
Body Construction, Regular Cab Page 3A–5
Page 3A–5
2.1 Front End & Underbody
Figure 3A – 1
Body Construction, Regular Cab Page 3A–6
Page 3A–6
Legend
1 Inner Rocker Panel Assembly, RH / LH
2 Seat Inner Bracket Assembly
3 Seat Outer Bracket Assembly, RH / LH
4 Front Floor Panel Assembly
5 Transmission Support Bracket, LH / RH
6 Front Floor Panel Extension
7 Front Side Rail Brace, RH/ LH
8 ABS Modulator Bracket Assembly, RH only
9 Front Wheelhouse Panel Assembly, RH / LH
10 Horn Bracket Assembly, LH only
11 Battery Tray Assembly, RH only
12 Front End Panel Assembly
13 Headlamp Panel, LH / RH
14 Radiator Lower Support Assembly
15 Headlamp & Front Fascia Mount Bracket, LH / RH
16 Fender Front Lower Bracket, LH / RH
17 Front Side Rail Assembly, LH / RH
18 Radiator Side Mounting Bracket, LH / RH
19 Front Wheelhouse Bracket Assembly, LH / RH
20 Front Bumper Impact Bar Bracket, LH / RH
21 Front Wheelhouse Panel Bracket, LH / RH
22 Inner Rocker Panel Filler, LH / RH
23 Jack Stowage Bracket, LH only
24 Rear Lower Body Panel Assembly, LH / RH
25 Front Floor Panel Plate (two places), LH / RH
26 Front Floor Panel Extension, LH
27 Propeller Shaft Hanger Assembly
28 Front Floor Panel Extension, RH
29 Rear Lower Body Panel
Body Construction, Regular Cab Page 3A–7
Page 3A–7
2.2 Upperbody Structure
Figure 3A – 2
Body Construction, Regular Cab Page 3A–8
Page 3A–8
Legend
1 Roof Front Header Panel
2 Roof Panel
3 Roof Rear Header Panel
4 Rear Body Upper Outer Panel Assembly
5 Rear Body Upper Inner Panel Assembly
6 Rear Body Lower Panel
7 Quarter Panel Inner Assembly, RH / LH
8 Quarter Panel Inner Extension, RH / LH
9 Hinge Pillar Trim Panel Bracket, RH / LH
10 Hinge Pillar Inner Panel Assembly, RH / LH
11 Front Wheelhouse Panel Upper Side Rail, RH / LH
12 Fender Upper Rear Bracket, RH / LH
13 Door Opening Frame Assembly, RH / LH
14 Front Door Striker Anchor Plate, RH / LH
15 Fender Lower Rear Bracket, RH / LH
16 Fender Rear Bracket, RH / LH
17 Underbody Jacking Locator, RH / LH
18 Quarter Panel Reinforcement, RH / LH
19 Rear Quarter Panel Assembly, RH / LH
20 Front Fender, RH / LH
Body Construction, Regular Cab Page 3A–9
Page 3A–9
2.3 Body Assembly
Figure 3A – 3
Body Construction, Regular Cab Page 3A–10
Page 3A–10
Legend
1 Body Assembly
2 Dash Panel Assembly
3 Front Bumper Impact Bar Assembly
4 Hood Assembly
5 Hood Hinge Assembly, RH / LH
6 Front Door Outer Panel, RH / LH
7 Front Door Assembly, RH / LH
8 Front Door Hinge (door side), RH / LH
9 Front Door Hinge (body side), RH / LH
10 Subframe Assembly
Body Construction, Regular Cab Page 3A–11
Page 3A–11
3 Body Dimensions
3.1 Underbody Dimensions – Projected
All dimensions are given in mm and are measured from the centre of holes, on the outer side of the metal surface.
The main datum surface (1) is the underside of the front side rail assembly, refer to Figure 3A–5.
The main datum hole (2) is a 19 mm hole on the underside of the front side rail assembly, refer to Figure 3A–5.
The dash panel assembly attaching hole (3) in Figure 3A –5 is also the same datum hole depicted at View C in
Figure 3A–4.
Body Construction, Regular Cab Page 3A–12
Page 3A–12
Figure 3A – 4
Body Construction, Regular Cab Page 3A–13
Page 3A–13
Figure 3A – 5
Body Construction, Regular Cab Page 3A–14
Page 3A–14
3.2 Upperbody Dimensions – Actual
Front
Figure 3A – 6
Body Construction, Regular Cab Page 3A–15
Page 3A–15
Side & Interior
Figure 3A – 7
Body Construction, Regular Cab Page 3A–16
Page 3A–16
4 Body Margins
Figure 3A – 8
Body Construction, Regular Cab Page 3A–17
Page 3A–17
Figure 3A – 9
Body Construction, Regular Cab Page 3A–18
Page 3A–18
5 Body Sealing, Adhesives &
Deadeners
5.1 Description
This Section describes the sealers, adhesives and deadener s used in the VY Regular Cab body structure. It is imperative
that the correct materials are used and the directions on the product are always followed.
The commercially available products listed
below will meet the required standards. Other
products may be available that meet the
performance characteristics, however before
their use, the product manufacturer should be
contacted to check its suitability.
NOTE
When replacing any sealer, adhesive or
deadener, ensure the finish meets that of the
original application as several different
techniques are used.
Weld Through Primer (Item 1)
Although not used in manufacture, Weld-Through Primer is recommended for all servic e repair lap and flange joints
where Acrylic Spot Weld Sealer (Item 2) is not used. Weld Through Primer aids in corrosion protection of the joint.
Acrylic Spot Weld Sealer (Item 2)
Used in joints that require sealing additional to Joint Sealer (Item 3). It is applie d to the joint flange prior to the mating of
panels. Refer to Figure 3A–10 to Figure 3A–13.
Joint Sealer (Item 3)
Primarily used for sealing joints to achieve a watertight seal. It seals notches, cut-outs and holes. Joint sealer sh ould be
applied after priming, prior to application of the top coat. Refer to Figure 3A–14 to Figure 3A–19.
Hand Putty (Item 4)
Hand putty, also known as caulking compound, is used in the areas marked * in Figure 3A–19.
Adhesive - Anti-Flutter (Item 5)
While used as a filler between an inner and outer panel to reduce panel flex. Anti-Flutter adhesive also aids rigidity and
assists in dispersing loads over a larger area. Refer to Figure 3A–20 for locations.
Adhesive - Structural (Item 6)
Critical to the strength and rigidity of the vehicle, the correct adhesive must be used for service repairs. Using an
adhesive that is too weak will reduc e the performance of the joint. Using an adhesive that is too strong can also effect the
performance of the joint, compromising the ve hicle’s crash performance and safety system’s operation. This adhesive is
a 2-part system. Refer to Figure 3A–21 & Figure 3A–22 for locations.
Spray-on Deadener (Item 7)
This deadener is spra yed onto the body shell after painting. It is used in the wheel-wells and on the under side of the
floor pan. A minimum thickness of 1.5 mm is required in the se applications. Refer to Figure 3A–23 for locations.
Body Construction, Regular Cab Page 3A–19
Page 3A–19
Floor Deadener Panels
Deadener panels are sold pre-cut as Service Parts. They are installed with the coloured side up and diamond embossed
side down. The panels are installed prior to painting. Some are heat fused to the body shell. Refer to Figure 3A–24 to
Figure 3A–26 for locations.
Commercially Available Sealer, Adhesive and Deadener Equivalents
Item No. Item Name Manufacturer Product Name
1 Weld Through Primer Not Specified – Refer to supplier
2 Acrylic Spot Weld Sealer Lord (Fusor) Fusor #800 / #801
3 Joint Sealer Sprayable: Lord (Fusor)
Extruded beads: Lord (Fusor)
3M
Visible Seams
-self levelling: Lord (Fusor)
3M
-non sag: Lord (Fusor)
3M
Fusor #802
Fusor #800 / #801
Automix 8308
Fusor #122 / #125
Automix 8307
Fusor #123 / #126
Automix 8308
4 Hand Putty Lord (Fusor)
3M
Fusor #800 / #801
Automix 8307
5 Adhesive - Anti Flutter Lord (Fusor) Fusor #124
6 Adhesive - Structural (two-part) Lord (Fusor)
3M
Fusor #108 B
Automix 8115
7 Spray-on Deadener Henkel Terophon 2000-13
NOTE
Special tools may be required to apply some
materials, refer to the supplier for further
information.
Body Construction, Regular Cab Page 3A–20
Page 3A–20
5.2 Acrylic Spot Weld Sealer (Item 2)
Figure 3A – 10
Legend
1 Door Opening Frame
2 Hinge Pillar Reinforcement
3 Hinge Pillar Inner Panel
4 Hinge Pillar Closing Plate
5 Front Wheelhouse Panel Upper Side Rail
Body Construction, Regular Cab Page 3A–21
Page 3A–21
Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3A – 11
Body Construction, Regular Cab Page 3A–22
Page 3A–22
Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3A – 12
Body Construction, Regular Cab Page 3A–23
Page 3A–23
Acrylic Spot Weld Sealer (Item 2) Continued
Figure 3A – 13
Body Construction, Regular Cab Page 3A–24
Page 3A–24
5.3 Joint Sealer (Item 3)
Figure 3A – 14
Body Construction, Regular Cab Page 3A–25
Page 3A–25
Joint Sealer (Item 3) Continued
Figure 3A – 15
Body Construction, Regular Cab Page 3A–26
Page 3A–26
Joint Sealer (Item 3) Continued
Figure 3A – 16
Body Construction, Regular Cab Page 3A–27
Page 3A–27
Joint Sealer (Item 3) Continued
Figure 3A – 17
Body Construction, Regular Cab Page 3A–28
Page 3A–28
Joint Sealer (Item 3) Continued
Figure 3A – 18
NOTE
When the inner rear body panel is installed, joint
sealer is applied around its perimeter between
the panel and body.
Body Construction, Regular Cab Page 3A–29
Page 3A–29
Joint Sealer (Item 3) Continued & Hand Putty (Item 4)
Figure 3A – 19
Body Construction, Regular Cab Page 3A–30
Page 3A–30
5.4 Adhesive – Anti-Flutter (Item 5)
Figure 3A – 20
Body Construction, Regular Cab Page 3A–31
Page 3A–31
5.5 Adhesive – Structural (Item 6)
Figure 3A – 21
Body Construction, Regular Cab Page 3A–32
Page 3A–32
Adhesive – Structural (Item 6) Continued
Figure 3A – 22
Body Construction, Regular Cab Page 3A–33
Page 3A–33
5.6 Spray-on Deadener
Figure 3A – 23
Body Construction, Regular Cab Page 3A–34
Page 3A–34
5.7 Deadeners & Insulators
The deadeners shown are heat fusible type. T hey are to be installed with the diamond embossed side down. Use a heat
gun, heat lamps or such to cure each deadener sheet.
Figure 3A – 24
Legend
1 Deadener - Front Floor, RH
2 Deadener - Front Floor, Centre
3 Deadener - Front Floor, LH
4 Deadener - Rear Floor, RH
5 Deadener - Rear Floor, Centre
6 Deadener - Floor Rear, LH
Body Construction, Regular Cab Page 3A–35
Page 3A–35
The insulator (1) is self-adhes ive. To install, remove the backing paper and attach the insulator ensuring any cut-outs
align with brackets etc. Smooth the insulator firmly into position. The deadener (2) is a heat cure t ype and is attache d a s
previously described.
Figure 3A – 25
Legend
1 Insulator - D ash Panel Upper 2 Deadener - Cockpit Module
The deadeners and insulators in Figure 3A – 26 are self-adhesive. Remove the backing paper and attach the insulator
ensuring any cut-outs align with brackets etc. Smooth the insulator firmly into position.
Figure 3A – 26
Legend
1 Insulator - Cowl Side, LH
2 Deadener - Front Floor Extension, LH 3 Deadener - Front Floor Extension, RH
4 Insulator - Cowl Side, RH
Body Construction, Regular Cab Page 3A–36
Page 3A–36
6 Cavity Wax
VY Regular Cab body and str uctural panels are constructed from high q uality corrosion resistant materials.
Following repairs, to maintain the anti-corrosive properties of the vehicle, once the p aint is thoroughly dry apply cavity
wax within any repaired b ox sections, areas inaccessible to paint, and to the areas shown below. Refer to the table for
equivalent products to those used in manufacture.
Cavity Wax Equivalents
Item No. Equivalent Manufacturer Equivalent Product Name
8 Henkel
Terotex HV 8377/65
Nox Rust Hi-Wax 100B
Terasol 800113 (Aerosol pack)
Figure 3A – 27
Body Construction, Regular Cab Page 3A–37
Page 3A–37
Figure 3A – 28