Cabin Floor, Regular Cab Page 6A–1
Page 6A–1
Section 6A
Cabin Floor, 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 ...............................................................................................................................2
1.1 Cabin Floor Components...................................................................................................................................... 2
2 Service Operations.................................................................................................................................4
2.1 Inner Rocker Panel Assembly – Replace............................................................................................................. 4
Remove................................................................................................................................................................... 4
Replace................................................................................................................................................................... 5
2.2 Rear Body Lower Panel Assembly – Replace ..................................................................................................... 8
Remove................................................................................................................................................................... 8
Replace................................................................................................................................................................. 10
2.3 Rear Body Lower Panel – Replace..................................................................................................................... 12
Remove................................................................................................................................................................. 12
Replace................................................................................................................................................................. 13
2.4 Jack Stowage Bracket – Replace ....................................................................................................................... 15
Remove................................................................................................................................................................. 15
Replace................................................................................................................................................................. 15
2.5 Front Floor Rear Extension – Replace............................................................................................................... 17
Remove................................................................................................................................................................. 17
Replace................................................................................................................................................................. 18
2.6 Front Floor Panel Assembly – Replace.............................................................................................................. 20
Remove................................................................................................................................................................. 20
Replace................................................................................................................................................................. 22
Cabin Floor, Regular Cab Page 6A–2
Page 6A–2
1 General Information
With the following exceptions VY Regular Cab Cabin Floor information carries over from MY 2003 VY Series vehicles.
• Cabin floor components
• Inner rocker panel assembly
• Rear body lower panel ass embly
• Rear body lower panel
• Jack stowage bracket
• Front floor rear extension, left-han d and right hand
• Front floor panel assembly
For information not contained within this Section, refer to Section 6 Cabin Floor in the MY 2003 VY and V2 Series
Service Information Supplement, Body Structure Repair. Removal of bolt-on panels and mecha nical components is not
covered. For information on the removal of these parts, reference must be made to the appropriate Section in the
MY 2004 VY Regular Cab and Crew Cab Service Information.
NOTE
• When repairing the cabin floor of the vehicle,
care must be taken to ensure the structure is
returned to its original production
configuration.
• It is imperative that the correct body
adhesives, sealers, deadeners and cavity
waxes are used when repairing the body
structure of VY Regular Cab vehicl es, refer to
Section 3A, 5 Body Sealing, Adhesives &
Deadeners and 6 Cavity Wax for details of the
correct materials and their commercially
available equivalents.
1.1 Cabin Floor Components
The shaded components are the cabin floor components
dealt with in this Section.
The components and assemblies shown in Figure 6A – 2
are the parts serviced for VY Regular Cab which form the
basis of the repair procedures in this Section. For a detaile d
view of the body components, refer to
Section 3A Body Construction, Regular Cab.
NOTE
Always refer to an Authorised Dealer for spare
parts availability configurations.
Figure 6A – 1
Cabin Floor, Regular Cab Page 6A–3
Page 6A–3
Figure 6A – 2
Legend
1 Inner Rocker Panel Assembly
2 Seat Inner Bracket Assembly*
3 Seat Outer Bracket Assembly, LH/ RH*
4 Front Floor Panel Assembly*
5 Transmission Support Bracket, LH/ RH*
6 Front Floor Panel Extension*
7 Jack Stowage Bracket
8 Floor Panel Plate Assembly, two each LH/ RH*
9 Propeller Shaft Hanger Assembly*
10 Front Floor Rear Extension Panel, LH
11 Front Floor Rear Extension Panel, RH
12 Rear Body Lower Panel
13 Rear Body Lower Panel Assembly, LH/ RH
* For replacement procedures refer to Section 6 Cabin Floo r in the MY 2003 VY and V2 Series Service Information
Supplement, Body Structure Repair.
Cabin Floor, Regular Cab Page 6A–4
Page 6A–4
2 Service Operations
2.1 Inner Rocker Panel Assembly – Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of the
MY 2004 VY Regular Cab and Crew Cab Service
Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the structural sections of the vehicle
on safety stands.
3 Remove the door opening fram e assembly and quarter
panel inner assembly, refer to
Section 7A Body Side, Regular Cab.
4 Remove other adjacent pane ls as required, refer to the
relevant Section in this Supplement.
Figure 6A – 3
5 Remove the MIG welds (1) attaching the inner rocker
panel to the hinge pillar inner assembly.
6 From underneath the vehicle, spot cut the welds
attaching the inner rocker panel assembly to the front
floor panel assembly. From inside (A), also spot cut
five welds, refer to Figure 6A – 5.
Figure 6A – 4
Figure 6A – 5
Cabin Floor, Regular Cab Page 6A–5
Page 6A–5
7 Spot cut the welds attaching the rear body lower
panel, the front floor rear extension an d the rear body
lower panel assembly to the inner rocker panel
assembly.
Figure 6A – 6
8 Spot cut the welds attaching the inner rocker panel
assembly to the front floor panel support (A), and the
centre crossmember (B).
9 Remove the inner rocker panel assembl y from the
vehicle and repair any damag e to adjacent panels as
required.
10 Check and rectify the alignme nt of the bod y as
required, refer to Section 3A, 3 Body Dimensions.
Figure 6A – 7
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment
available will not access the required weld
position, a plug weld should be performed.
The same number and position of spot welds (or
plug welds) should be used when replacing the
panel, as was used during manufacture, in order
to maintain the original structural strength of the
vehicle.
1 As required, mark the new panel with drilling locations in preparation for pl ug welding. Drill holes as requ ired.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3A,
5 Body Sealing, Adhesives & Dea deners.
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
4 Clamp the inner rocker panel assembly in position, noting to ensure it fits behind the lower edge of the hi nge pillar
inner assembly.
Cabin Floor, Regular Cab Page 6A–6
Page 6A–6
5 Spot or plug weld the inner rocker panel assembly to
the centre crossmember (B) and front floor panel
support (A).
Figure 6A – 8
6 Spot or plug weld the rear body lower panel, the front
floor rear extension and the rear body lower panel
assembly to the inner rocker panel assembly.
7 From underneath the vehicle, spot or plug weld the
inner rocker panel assembly to the front floor panel
assembly. From inside (A), also spot or plug weld five
places, refer to Figure 6A – 10.
Figure 6A – 9
Figure 6A – 10
Cabin Floor, Regular Cab Page 6A–7
Page 6A–7
8 Make six MIG welds (1) to attach inner rocker panel
assembly to the hinge pillar inner assembly.
9 Replace the adjoining removed panels as required,
refer to the relevant Section in this Supplement.
10 Refinish and paint panels and other components as
the VY and V2 Series Service Information
Supplement, Body Structure Repair.
11 Apply Joint Sealer (Item 3) as required. refer to
Section 3A, 5 Body Sealing, Adhesives & Deadeners.
12 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint, refer
to Section 3A, 6 Cavity Wax.
13 Reinstall the remaining bolt-on panels and
components as required, refer to the appropriate
Section of the MY 2004 VY Regular Cab an d Crew
Cab Service Information.
Figure 6A – 11
required, refer to Section 3, 1.3 Paint Refinishin g in
Cabin Floor, Regular Cab Page 6A–8
Page 6A–8
2.2 Rear Body Lower Panel Assembly –
Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of the
MY 2004 VY Regular Cab and Crew Cab Service
Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the structural sections of the vehicle
on safety stands.
3 Remove other adjacent pane ls as required, refer to the
relevant Section in this Supplement.
Figure 6A – 12
4 Spot cut the welds attaching the rear body lower panel
assembly to the rear body lower panel.
Figure 6A – 13
5 From underneath the vehicle, spot cut the welds
attaching the rear body lower panel assembly to the
front floor rear extension p anel.
Figure 6A – 14
Cabin Floor, Regular Cab Page 6A–9
Page 6A–9
6 Spot cut the welds attaching the rear body lower panel
assembly to the inner rocker panel assembly.
7 Spot cut the welds attaching the rear body lower panel
assembly to the rear body lower panel and the front
floor panel rear extension, refer to Figure 6A – 16.
Figure 6A – 15
Figure 6A – 16
8 Remove the rear body lower panel assembly from the vehicle and repair an y damage to adjacent panels as
required.
9 Check and rectify the alignme nt of the body as required, refer to Section 3A, 3 Body Dimensions.
Cabin Floor, Regular Cab Page 6A–10
Page 6A–10
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment
available will not access the required weld
position, a plug weld should be performed.
The same number and position of spot welds (or
plug welds) should be used when replacing the
panel, as was used during manufacture, in order
to maintain the original structural strength of the
vehicle.
1 As required, mark the new panel with drilling locations in preparation for pl ug welding. Drill holes as requ ired.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3A,
5 Body Sealing, Adhesives & Dea deners.
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
4 Spot or plug weld the rear body lower panel assembly to the rear body lower panel and the front floor panel rear
extension, refer to Figure 6A – 17.
Figure 6A – 17
Cabin Floor, Regular Cab Page 6A–11
Page 6A–11
5 Spot or plug weld the rear body lower panel assembly
to the inner rocker panel asse mbly.
Figure 6A – 18
6 Spot or plug weld the rear body lower panel assembly
to the front floor panel rear extension.
Figure 6A – 19
7 Spot or plug weld the rear body lower panel assembly
to the rear body lower panel.
8 Replace the adjoining removed panels as required,
refer to the relevant Section in this Supplement.
9 Refinish and paint panels and other components as
the VY and V2 Series Service Information
Supplement, Body Structure Repair.
10 Apply Joint Sealer (Item 3) as required. refer to
Section 3A, 5 Body Sealing, Adhesives & Deadeners.
11 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint, refer
to Section 3A, 6 Cavity Wax.
12 Reinstall the remaining bolt-on panels and
components as required, refer to the appropriate
Section of the MY 2004 VY Regular Cab an d Crew
Cab Service Information.
Figure 6A – 20
required. refer to Section 3, 1.3 Paint Refinishin g in
Cabin Floor, Regular Cab Page 6A–12
Page 6A–12
2.3 Rear Body Lower Panel – Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of the
MY 2004 VY Regular Cab and Crew Cab Service
Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the structural sections of the vehicle
on safety stands.
3 Remove the welds attaching the rear body lower
panel, refer to Section 10A,
2.1 Rear Body Lower Panel.
4 Remove the left-hand and right-hand rear body lower
panel assemblies, refer to
2.2 Rear Body Lower Panel Assembly – Replace.
5 Remove other adjacent pane ls as required, refer to the
relevant Section in this Supplement.
Figure 6A – 21
6 Spot cut the welds attaching the rear body lower panel
to the quarter panel inner assembly.
7 Spot cut the welds attaching the rear body lower panel
to the front floor panel rear extension and the inner
rocker panel assembly, refer to Figure 6A – 23.
Figure 6A – 22
Cabin Floor, Regular Cab Page 6A–13
Page 6A–13
Figure 6A – 23
8 Remove the rear body lower panel from the vehicle and repair any d amage to adjacent panels as requir ed.
9 Check and rectify the alignme nt of the body as required, refer to Section 3A, 3 Bod y Dimensions.
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment
available will not access the required weld
position, a plug weld should be performed.
The same number and position of spot welds (or
plug welds) should be used when replacing the
panel, as was used during manufacture, in order
to maintain the original structural strength of the
vehicle.
1 As required, mark the new panel with drilling locations in preparation for pl ug welding. Drill holes as requ ired.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3A,
5 Body Sealing, Adhesives & Dea deners.
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
4 Plug or spot weld the rear body lower panel to the front floor panel rear ext ension and the inner rocker panel, refer
to Figure 6A – 24.
Cabin Floor, Regular Cab Page 6A–14
Page 6A–14
Figure 6A – 24
5 Plug or spot weld the rear body lower panel to the
quarter panel inner assembly.
6 Replace the adjoining removed panels as required,
refer to the relevant Section in this Supplement.
7 Refinish and paint panels and other components as
required. refer to Section 3, 1.3 Paint Refinishin g in
the VY and V2 Series Service Information
Supplement, Body Structure Repair.
8 Apply Joint Sealer (Item 3) as required. refer to
Section 3A, 5 Body Sealing, Adhesives & Deadeners.
9 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint, refer
to Section 3A, 6 Cavity Wax.
10 Reinstall the remaining bolt-on panels and
components as required, refer to the appropriate
Section of the MY 2004 VY Regular Cab an d Crew
Cab Service Information. Figure 6A – 25
Cabin Floor, Regular Cab Page 6A–15
Page 6A–15
2.4 Jack Stowage Bracket – Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of the
MY 2004 VY Regular Cab and Crew Cab Service
Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the structural sections of the vehicle
on safety stands.
3 Remove other adjacent pane ls as required, refer to the
relevant Section in this Supplement.
Figure 6A – 26
4 Spot cut the welds attaching the jack stowage bracket
to the front floor panel assembly.
5 Remove the jack stowage bracket from the vehicle
and repair any damage to adjacent panels as required.
Figure 6A – 27
Replace
1 As required, mark the new panel with drilling locations in preparation for pl ug welding. Drill holes as requ ired.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as requir ed, refer to Section 3A,
5 Body Sealing, Adhesives & Dea deners.
Cabin Floor, Regular Cab Page 6A–16
Page 6A–16
3 Spot or plug weld the jack stowage bracket to the front
floor panel assembly.
4 Replace the adjoining removed panels as required,
refer to the relevant Section in this Supplement.
5 Refinish and paint panels and other components as
required. refer to Section 3, 1.3 Paint Refinishin g in
the VY and V2 Series Service Information
Supplement, Body Structure Repair.
6 Apply Joint Sealer (Item 3) as required. refer to
Section 3A, 5 Body Sealing, Adhesives & Deadeners.
7 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint, refer
to Section 3A, 6 Cavity Wax.
8 Reinstall the remaining b olt-on panels and
components as required, refer to the appropriate
Section of the MY 2004 VY Regular Cab an d Crew
Cab Service Information. Figure 6A – 28
Cabin Floor, Regular Cab Page 6A–17
Page 6A–17
2.5 Front Floor Rear Extension – Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of the
MY 2004 VY Regular Cab and Crew Cab Service
Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the structural sections of the vehicle
on safety stands.
3 Remove the rear body lower panel, refer to
2.3 Rear Body Lower Panel – Repl ace.
4 For the left-hand side, remove the jack stowage
bracket, refer to
2.4 Jack Stowage Bracket – Replace.
5 Remove other adjacent pane ls as required, refer to the
relevant section in this Supplement. Figure 6A – 29
6 If required, from underneath the vehicle, sp ot cut the
welds attaching the pressure hose support to the front
floor panel rear extension.
7 Spot cut the welds attaching the front floor panel rear
extension to the front floor panel assembly and the
inner rocker panel assembly, refer to Figure 6A – 31.
NOTE
If both sides are being replaced it is not
necessary to remove the welds attaching the
left-hand side to the right-hand side extensi on.
Figure 6A – 30
Cabin Floor, Regular Cab Page 6A–18
Page 6A–18
Figure 6A – 31
8 Remove the front floor panel rear extension bracket from the vehicle and repair any damage to adjacent panels as
required.
9 Check and rectify the alignme nt of the body as required, refer to Section 3A, 3. Body Dimensions.
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment
available will not access the required weld
position, a plug weld should be performed.
The same number and position of spot welds (or
plug welds) should be used when replacing the
panel, as was used during manufacture, in order
to maintain the original structural strength of the
vehicle.
1 As required, mark the new panel with drilling locations in preparation for pl ug welding. Drill holes as requ ired.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as requir ed, refer to Section 3A,
5 Body Sealing, Adhesives & Dea deners.
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
Cabin Floor, Regular Cab Page 6A–19
Page 6A–19
4 Plug or spot weld the pressure hose support to the
front floor panel rear extension.
5 Secure the front floor panel rear extensio n in position
and make several tack welds around its
circumference. Spot or plug weld to the front floor
panel assembly and the inner rocker panel assembly,
refer to Figure 6A – 33.
NOTE
If only one side of the rear extension is to be
replaced, spot or plug the welds to attach the
left-hand extension to the right-hand extension.
Ensure that the extension on the left hand side is
positioned correctly under the extension on the
right hand side.
Figure 6A – 32
Figure 6A – 33
6 Replace the adjoining removed panels as required, refer to the relevant Se ction in this Supplement.
7 Refinish and paint panels and other components as required. Refer to Section 3, 1.3 Paint Refinishing in the VY
and V2 Series Service Information Supplement, Body Structure Repair.
8 Apply Joint Sealer (Item 3) as required. Refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
9 Apply Cavity Wax (Item 8) as required to the inside of any box sections or areas inaccessible to paint, refer to
Section 3A, 6 Cavity Wax.
10 Apply floor deadeners as req uired, refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
11 Apply Spray-On Deadener (Item 7) as required to the underside of the floor, refer to Section 3A,
5 Body Sealing, Adhesives & Dea deners.
12 Reinstall the remaining bolt-on panels and components as requ ired, refer to the appropriate Section of the
MY 2004 VY Regular Cab and Crew Cab Service Information.
Cabin Floor, Regular Cab Page 6A–20
Page 6A–20
2.6 Front Floor Panel Assembly – Replace
Remove
Care must be taken to avoid cutting the fuel,
brake or emission control pipes.
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate section of the MY 2004
VY Regular Cab and Crew Cab Service Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the structural sections of the vehicle
on safety stands.
3 Using a scraper and heat gun, remove the body sealer
and deadener from the front floor attaching areas as
required.
4 Remove the jack stowage bracket, refer to
2.4 Jack Stowage Bracket – Replace.
5 Remove other adjoining panels as required, refer to
the relevant Section in this Supplement. Figure 6A – 34
6 From underneath each side of the vehicle, spot cut the welds attaching the front floor panel assembly to the inner
rocker panel assembly. From inside (A), also spot cut five welds, refer to Figure 6A – 35.
Figure 6A – 35
Cabin Floor, Regular Cab Page 6A–21
Page 6A–21
7 Grind the MIG weld (1) attaching the front floor panel
extension to the front floor panel assembly.
8 Spot cut the welds attaching the front floor panel
extension to the front floor panel assembly.
9 Spot cut the welds attaching the front floor panel
assembly to the front side rail assemblies, each side of
the vehicle, refer to Figure 6A – 37.
Figure 6A – 36
Figure 6A – 37
10 Spot cut the welds attaching the front floor panel rear extension to the fron t floor panel assembly, refer to
Figure 6A – 38.
Cabin Floor, Regular Cab Page 6A–22
Page 6A–22
Figure 6A – 38
11 Remove the front floor assembly from the vehicle and repair any damage to adjacent panels as required.
12 Check and rectify the alignme nt of the body as required, refer to Section 3A, 3 Body Dim ensions.
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment
available will not access the required weld
position, a plug weld should be performed.
The same number and position of spot welds (or
plug welds) should be used when replacing the
panel, as was used during manufacture, in order
to maintain the original structural strength of the
vehicle.
1 As required, mark the new panel with drilling locations in preparation for pl ug welding. Drill holes as requ ired.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3A,
5 Body Sealing, Adhesives & Dea deners.
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
4 Secure the front floor panel assembly in position and mak e severa l tack welds around its circumference.
5 Spot or plug weld the front floor panel assembly to the front floor panel rear extensio n and the inner rocker panel
assembly, refer to Figure 6A – 39.
Cabin Floor, Regular Cab Page 6A–23
Page 6A–23
Figure 6A – 39
6 On each side of the vehicle, spot or plug weld the front floor panel assembly to the front side rail assemblies, refer
to Figure 6A – 40.
Figure 6A – 40
Cabin Floor, Regular Cab Page 6A–24
Page 6A–24
7 Spot or plug weld the front floor panel extension to the
front floor panel assembly.
8 MIG weld (1) the front floor panel extension to the front
floor panel assembly.
9 From underneath each side of the vehicle, spot or plug
weld the front floor panel assembly to the inner rocker
panel assembly. From inside (A), also spot o r plug
weld five places, refer to Figure 6A – 42.
Figure 6A – 41
Figure 6A – 42
10 Replace any other remov ed panels as required, refer to the relevant Section in this Supplement.
11 Refinish and paint panels and other components as required. Refer to Section 3, 1.3 Paint Refinishing in the VY
and V2 Series Service Information Supplement, Body Structure Repair.
12 Apply Joint Sealer (Item 3) as required, refer to Section 3A, 5 Body Sealing, Adhesives & Dea deners.
13 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint, refer to
Section 3A, 6 Cavity Wax.
14 Apply floor deadeners as req uired, refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
15 Apply Spray-On Deadener (Item 7) as required to the underside of the floor, refer to Section 3A,
5 Body Sealing, Adhesives & Dea deners.
16 Reinstall the remaining bolt-on panels and components as requ ired, refer to the appropriate Section of the
MY 2004 VY Regular Cab and Crew Cab Service Information.