Body Side, Regular Cab Page 7A–1
Page 7A–1
Section 7A
Body Side, 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 wo rkshop 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 Body Side Components ........................................................................................................................................ 2
2 Service Operations.................................................................................................................................5
2.1 Rear Quarter Panel Assembly – Replace............................................................................................................. 5
Remove................................................................................................................................................................... 5
Replace................................................................................................................................................................... 6
2.2 Rear Quarter Panel Reinforcement – Replace..................................................................................................... 8
Remove................................................................................................................................................................... 8
Replace................................................................................................................................................................... 9
2.3 Door Opening Frame Assembly – Replace........................................................................................................ 10
Remove................................................................................................................................................................. 10
Replace................................................................................................................................................................. 14
2.4 Door Opening Frame Assembly – Partial Replace, Hinge Pillar...................................................................... 19
Remove................................................................................................................................................................. 19
Replace................................................................................................................................................................. 22
2.5 Door Opening Frame Assembly – Partial Replace, Centre Pillar..................................................................... 27
Remove................................................................................................................................................................. 27
Replace................................................................................................................................................................. 29
2.6 Quarter Panel Inner Assembly – Replace.......................................................................................................... 33
Remove................................................................................................................................................................. 33
Replace................................................................................................................................................................. 35
Body Side, Regular Cab Page 7A–2
Page 7A–2
1 General Information
With the following exceptions, VY Regular Cab body side information carries over from MY 2003 VY Ser ies vehicles.
• Body side components
• Rear quarter panel assembly
• Rear quarter panel reinforce ment
• Door opening frame assembl y
• Quarter panel inner assembly
For information not contained within this Section, refer to Section 7 Body Side in the MY 2003 VY and V2 Series Service
Information Supplement, Body Structure Repair. Removal of bolt-on panels and mechanical compone nts 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 S ervice Information.
This Section includes door opening frame assembly partial repl acement procedures for the hinge pillar, centre pillar and
rocker panel. These procedures must be followed carefully, as they can involve hidden re inforcement panels. The cutting
locations specified are the only places allowable.
NOTE
• When repairing the body side of the vehicle,
care must be taken to ensure the structure is
returned to its original production
configuration. This is especially important to
maintain side impact standards.
• 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 and
Deadeners and 6 Cavity Wax for details of the
correct materials and their commercially
available equivalents.
1.1 Body Side Components
NOTE
Always refer to an Authorised dealer for spare
parts availability configurations.
Cavity foam may be used within the hinge,
and centre pillars. Care needs to be taken
when repairing the vehicle in these areas.
Refer to Section 2, 10.1 Cavity Foam in the MY
2003 VY and V2 Series Service Information
Supplement, Body Structure Repair prior to
beginning any work for further information.
Body Side, Regular Cab Page 7A–3
Page 7A–3
The shaded components shown are the body side
components dealt with in this Section.
The components and assemblies shown in Figure 7A – 2
are the parts serviced for the VY Regular Cab vehicles
which form the basis of the repair procedures in this
Section. For a detailed 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 7A – 1
Figure 7A – 2
Body Side, Regular Cab Page 7A–4
Page 7A–4
Legend
1 Quarter Panel Inner Assembly
2 Quarter Panel Inner Extension*
3 Hinge Pillar Trim Panel Bracket*
4 Hinge Pillar Inner Panel Assembly*
5 Fender Upper Rear Bracket
6 Door Opening Frame Assembly
7 Door Striker Anchor Plate
8 Fender Lower Rear Bracket
9 Fender Rear Bracket
10 Underbody Jacking Locator
11 Inner Rocker Panel Filler LH/ RH
12 Rear Quarter Panel Reinforcement
13 Rear Quarter Panel Assembly
The door opening frame assembly includes parts 5, 7, 8, 9, 10 and 11.
* For replacement procedures refer to Section 7C Body Side – Utility in the MY 2003 VY and V2 S eries Service
Information Supplement, Body Structure Repair.
Body Side, Regular Cab Page 7A–5
Page 7A–5
2 Service Operations
2.1 Rear Quarter Panel Assembly – Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2004 VY Regular Cab and Crew Cab Service
Information.
2 Remove the rear and quarter windows, refer to
Section 1A6 Stationary Windows in the MY 2 004 VY
Regular Cab and Crew Cab S ervice Information.
3 Remove other adjacent pane ls as required, refer to the
relevant Section in this Supplement.
Figure 7A – 3
4 Spot cut the welds attaching the rear quarter panel
assembly to the door opening frame.
Figure 7A – 4
Body Side, Regular Cab Page 7A–6
Page 7A–6
5 Spot cut the welds attaching the rear quarter panel
assembly to the door opening frame assembly.
6 Remove the rear quarter panel assembl y from the
vehicle and repair any damag e to adjacent parts as
required.
NOTE
Acrylic spot weld sealer is used in many of the
joints which may require prisi ng apart.
7 Check and rectify the alignme nt of the bod y as
required, refer to Section 3A, 3 Body Dimensions.
Figure 7A – 5
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment 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 plug welding. Drill holes as required.
2 Prepare all mating surfaces and treat with weld through primer (Item 1) as required, refer to Section 3A,
5 Body Sealing, Adhesives and Dea de ners.
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
4 Clamp the rear quarter panel assemb ly in position.
Body Side, Regular Cab Page 7A–7
Page 7A–7
5 Spot or plug weld the rear quarter panel ass embl y to
the door opening frame assembly.
Figure 7A – 6
6 Spot or plug weld the rear quarter panel ass embl y to
the door opening frame assembly.
7 Replace the adjoining removed panels as required,
refer to the relevant Section in this Supplement.
8 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.
9 Apply Joint Sealer (Item 3) as required. Refer to
Section 3A, 5 Body Sealing, Adhesives a nd
Deadeners.
10 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 .
11 Replace the rear and quarter wind ows, refer to Section
1A6 Stationary Windo ws in the MY 2004 VY Reg ular
Cab and Crew Cab Service Information.
12 Install the remaining components as described in the
appropriate Section in the MY 2004 VY Regular Cab
and Crew Cab Service Information.
Figure 7A – 7
Body Side, Regular Cab Page 7A–8
Page 7A–8
2.2 Rear Quarter Panel Reinforcement –
Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section in the MY
2004 VY Regular Cab and Crew Cab Service
Information.
2 Remove the rear quarter panel, refer to
2.1 Rear Quarter Panel Assembly – Replace.
3 Remove other adjacent pane ls as required, refer to the
relevant Section in this Supplement.
Figure 7A – 8
4 Spot cut the welds attaching the rear quarter panel
reinforcement to the door opening frame ass embl y
and quarter panel inner ass embly.
NOTE
Remove any additional welds not previously
removed with adjacent panels as required.
5 Remove the rear quarter panel reinforcement from the
vehicle and repair any damag e to adjacent parts as
required.
6 Check and rectify the alignme nt of the bod y as
required, refer to Section 3A, 3 Body Dimensions.
Figure 7A – 9
Body Side, Regular Cab Page 7A–9
Page 7A–9
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment 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 plug welding. Drill holes as required.
2 Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to Section
3A, 5 Body Sealing, Adhesives and Dead eners.
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to
Section 3A, 5 Body Sealing, Adhesives a nd
Deadeners.
4 Clamp the panel in position.
5 Spot or plug weld the rear quarter panel reinforcement
to the door opening frame assembly and q ua r ter panel
inner assembly.
6 Replace the adjoining removed panels as required,
refer to the relevant Section in this Supplement.
7 Replace the adjoining removed panels as required,
refer to the relevant Section in this Supplement.
8 Refinish and paint panels and other components as
required. Refer to Section 3, 1.3 Paint Refinishing in
the MY 2003 VY and V2 Series Service Inform ation
Supplement, Body Structure Repair.
9 Apply Joint Sealer (Item 3) as required. Refer to
Section 3A, 5 Body Sealing, Adhesives a nd
Deadeners. Figure 7A – 10
10 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 .
11 Install the remaining compon ents as described in the appropriate Secti on in the MY 2004 VY Regular Cab and
Crew Cab Service Information.
Body Side, Regular Cab Page 7A–10
Page 7A–10
2.3 Door Opening Frame Assembly –
Replace
NOTE
This procedure requires the removal of the roof
panel. As an alternative, the door opening frame
assembly can be separated at the upper pillar
sections by following the procedures in Door
Opening Frame Assembly – Partial Replace,
Hinge Pillar and Centre Pillar in this Sectio n.
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2004 VY Regular Cab and Crew Cab Service
Information.
2 Remove the front door assembly, refer to
Section 8 Doors, Liftgate & Endgate in the MY 2003
VY and V2 Series Service Information Supplement,
Body Structure Repair.
3 Remove the windshield, quarter window and rear
window, refer to Section 1A6, Stationary Windows in
the MY 2004 VY Regular Cab and Crew Cab Service
Information.
4 Remove the dash panel retaining bolt from the hinge
pillar. Figure 7A – 11
5 Remove the roof panel, refer to Section 9, Roof in the VY and V2 Series Service Information Supplement, Bod y
Structure Repair.
6 Remove the rear quarter panel, refer to 2.1 Rear Quarter Panel – Replac e.
7 Remove the rear quarter panel reinforcement, refer to 2.2 Rear Quarter Panel Reinforcement – Replace.
8 Remove the front wheelhouse panel upper side rail, refer to Section 4,
2.5 Front Wheelhouse Panel Upper Side Rail in the MY 2003 VY and V2 Series Service Information Supplem ent,
Body Structure Repair.
9 Remove other adjacent pane ls as required, refer to the relevant Section in this Supplement.
10 Spot cut along the vertical flange below the rocker panel to separate the door opening frame assembly from the
inner rocker panel, refer to Figure 7A – 12.
Figure 7A – 12
11 Spot cut from below, up into the rocker panel, the welds attaching the door opening frame assembly to the quarter
panel inner assembly, refer to Figure 7A – 13.
Body Side, Regular Cab Page 7A–11
Page 7A–11
Figure 7A – 13
12 Spot cut the welds attaching the door openin g frame
assembly to the inner rocker panel and to the hin ge
pillar inner panel assembly.
NOTE
In order to spot cut the uppermost of these welds
it may be necessary to cut and peel back the
section of hinge reinforcement panel covering
the welds, to gain the required access.
Figure 7A – 14
13 Spot cut the two welds at the base of the hinge pillar,
attaching the door opening frame assembly (1) to the
hinge pillar inner panel assembly (2).
Figure 7A – 15
Body Side, Regular Cab Page 7A–12
Page 7A–12
14 Spot cut the welds on the windshield side flange,
attaching the door opening frame assembly (1) to the
hinge pillar inner panel assembly (2).
Figure 7A – 16
15 As required, spot cut the welds along the roof flange.
NOTE
Many of these welds may have been removed
with the roof panel.
Figure 7A – 17
16 Spot cut the welds attaching the door openin g frame
assembly to the roof rear panel.
Figure 7A – 18
Body Side, Regular Cab Page 7A–13
Page 7A–13
17 Spot cut the welds attaching the door openin g frame
assembly to the side inner upper front panel, side
inner upper panel and quarter panel inner assembly.
Figure 7A – 19
18 Spot cut the welds on the flange surrounding the front
door opening, attaching the door op ening frame
assembly to the hinge pillar inner assembly, inner
rocker panel and quarter panel in ner assembly.
19 Remove the door opening fram e assembly and repair
any damage to adjacent parts as required.
20 Check and rectify the alignme nt of the bod y as
required, refer to Section 3A, 3 Body Dimensions.
Figure 7A – 20
Body Side, Regular Cab Page 7A–14
Page 7A–14
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment 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 plug welding. Drill holes as required.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3A,
5 Body Sealing, Adhesives and Dea de ners.
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3A, 5 Body Seali ng, Adhesives and Deadeners.
4 Securely clamp the door openin g frame assembly in position on the vehicle bod y.
5 Spot or plug weld around the front door opening
flange.
Figure 7A – 21
Body Side, Regular Cab Page 7A–15
Page 7A–15
6 Spot or plug weld the door opening frame assembly to
the side inner upper front panel, side inner u pper
panel and quarter pane l inner assembly.
Figure 7A – 22
7 Spot weld the door opening frame assembly to the
roof rear panel.
Figure 7A – 23
Body Side, Regular Cab Page 7A–16
Page 7A–16
8 Spot or plug weld the door opening frame assembly
along the roof flange several places.
NOTE
The remaining welds are made when the roof
panel is installed.
Figure 7A – 24
9 Spot weld along the windshield flange, attaching the
door opening frame assembly to the hinge pillar inner
panel assembly.
Figure 7A – 25
10 Spot weld in two places at the base of the hinge pillar,
attaching the door opening frame assembly (1) to the
hinge pillar inner panel assembly (2).
Figure 7A – 26
Body Side, Regular Cab Page 7A–17
Page 7A–17
11 Spot or plug weld the door opening frame assembly to
the inner rocker panel and to the hinge pillar inner
panel assembly.
NOTE
If the sheet metal was modified to allow access
to these welds, it should be repaired to its
original configuration.
12 Plug weld up through the rocker panel to attach the
door opening frame assembly to the quarter p anel
inner assembly, refer to Figure 7A – 28.
Figure 7A – 27
Figure 7A – 28
13 Spot weld the door opening frame assembly along the vertical flange below the rocker panel, refer to
Figure 7A – 29
Figure 7A – 29
14 Replace the front wheelhouse panel upper side rail, refer to Section 4,
2.5 Front Wheelhouse Panel Upper Side Rail in the MY 2003 VY and V2 Series Service Information Sup plement,
Body Structure Repair.
15 Replace the roof panel, refer to Section 9, Roof.
16 Replace the rear quarter panel reinforceme nt, refer to 2.2 Rear Quarter Panel Reinforcement – Replace.
Body Side, Regular Cab Page 7A–18
Page 7A–18
17 Replace the rear quarter panel, refer to 2.1 Rear Quarter Pane l – Replace.
NOTE
Refinish and prime any bare metal as required
prior to replacing these panel s.
18 Install the door hinges, refer to Section 8 Do ors, Liftgate & Endgate in the MY 2003 VY and V2 Series Service
Information Supplement, Body Structure Repair.
19 Replace other adjoining removed pane ls as required, refer to the relevant Section in this Supplement.
20 Refinish and paint panels and other components as required. Refer to Section 3, 1.3 Paint Refinishing in the MY
2003 VY and V2 Series Service Information Supplement, Body Structure Repair.
21 Apply Joint Sealer (Item 3) as required. Refer to Section 3A, 5 Body Sealing, Adhesives and Deadeners.
22 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.
23 Apply Spray-on Dea de ner (Item 7) where applicable, refer to Section 3A,
5 Body Sealing, Adhesives and Dea de ners.
24 Install the dash panel retaining bolt throu gh the hinge pillar and tighten to the specified torque.
Dash panel retaining b olt
torque specification.........................................35.0 – 45.0 Nm
25 Replace the windshield, quarter glass and rear window, refer to Section 1A6 Stationary Gl ass in the MY 2004 VY
Regular Cab and Crew Cab S ervice Information.
26 Insert Cavity Foam into the hinge and centre pillars as required, refer to Section 2, 10.1 Cavity Foam in the MY
2003 VY and V2 Series Service Information Supplement, Body Structure Repair.
27 Install the remaining compon ents as described in the appropriate Secti on in the MY 2004 VY Regular Cab and
Crew Cab Service Information.
Body Side, Regular Cab Page 7A–19
Page 7A–19
2.4 Door Opening Frame Assembly – Partial
Replace, Hinge Pillar
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2004 VY Regular Cab and Crew Cab Service
Information.
2 Remove the front door assembly, refer to
Section 8 Doors, Liftgate & Endgate in the MY 2003
VY and V2 Series Service Information Supplement,
Body Structure Repair.
3 Remove the windshield, refer to
Section 1A6, Stationary Windows in the MY 2004 VY
Regular Cab and Crew Cab S ervice Information.
4 Remove the dash panel retaining bolt from the hinge
pillar.
5 Remove the front wheelhouse pan el upper side rail,
refer to Section 4,
2.5 Front Wheelhouse Panel Upper Side Rail in the
MY 2003 VY and V2 Series Service Information
Supplement, Body Structure Repair.
6 Remove other adjacent pane ls as required, refer to the
relevant Section in this Supplement.
7 Secure an appropriate tool between the front door
opening flanges to maintain correct bod y alignment.
Figure 7A – 30
8 Spot cut the welds attaching the door openin g frame
assembly to the inner rocker panel and to the hin ge
pillar inner panel assembly.
NOTE
In order to spot cut the uppermost of these welds
it may be necessary to cut and peel back the
section of hinge reinforcement panel covering
the welds, to gain the required access.
Figure 7A – 31
Body Side, Regular Cab Page 7A–20
Page 7A–20
9 Spot cut the two welds at the base of the hinge pillar,
attaching the door opening frame assembly (1) to the
hinge pillar inner panel assembly (2).
Figure 7A – 32
10 Select a cutting point on the hinge pillar. This cut point
should be within the region specified.
Figure 7A – 33
11 At the selected point (1), cut through the outer and
reinforcement panels, leaving the inner panel intact.
12 Mark the inner panel at points 50 mm either side of the
cut line on the outer panel and cut the inner panel at
these two points (2). Spot cut the welds and remove
the 100 mm section of inner panel (3).
Figure 7A – 34
Body Side, Regular Cab Page 7A–21
Page 7A–21
13 Spot cut the welds on the windshield side flange, up to
the point of the cut.
Figure 7A – 35
14 Cut through the rocker panel section of the door
opening frame assembly. The cut point (1) sh ould be
approximately 100 mm from the dimple (2) on the
flange. Cut through both the outer pane l and the
reinforcement panel.
Figure 7A – 36
15 Spot cut the welds on the flange along the front door
opening, from the cut near the top of the hinge pill ar
(1) to the cut in the rocker panel (2).
16 Spot cut the welds along the flange (3) below the
rocker panel (to the point of the cut), separ ating the
door opening frame assembly from the inner rocker
panel.
17 Remove the partial hinge p illar from the vehicle, then
repair any damage to adjacent parts.
18 Check and rectify the alignme nt of the bod y as
required, refer to Section 3A, 3 Body Dimensions.
Figure 7A – 37
Body Side, Regular Cab Page 7A–22
Page 7A–22
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment 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 Cut a replacement panel section (1), accurately
measuring the position of cuts to match the section
removed.
Figure 7A – 38
2 Remove a section of inner rocker panel (1), cut 50 mm
each side of the cut in the rocker panel (2). This all ows
access for welding the rocker panel reinf orcement.
Figure 7A – 39
Body Side, Regular Cab Page 7A–23
Page 7A–23
3 Either manufacture a new section or cut an existing
length of surplus rocker panel section, to form a
reinforcement (1), approximately 100 mm in length.
4 Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to Section
3A, 5 Body Sealing, Adhesives and Dead eners.
5 Clamp this reinforcement firmly behind the cut section
of rocker panel on the vehicle and spot or plug weld in
place. Position welds at a maximum spacing of 35 mm
apart.
Figure 7A – 40
6 Using a similar technique, ma nufacture or cut a
section of reinforcement panel (1) (appro xim ately 60
mm long) to fit on the inside of the replacement hinge
pillar outer panel (2) at the point of the cut.
NOTE
Remove the flanges from this reinforcement
panel.
7 Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to Section
3A, 5 Body Sealing, Adhesives and Dead eners.
8 Clamp the reinforcement panel firmly behind the cut
section of the hinge pillar outer and spot weld (3) in
place.
9 Mark the new hinge pillar pan el with drilling locations
in preparation for plug welding where required. Drill
holes as marked.
10 Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to Section
3A, 5 Body Sealing, Adhesives and Dead eners.
11 Apply Acrylic Spot Weld Sealer (Item 2), refer to
Section 3A, 5 Body Sealing, Adhesives a nd
Deadeners.
Figure 7A – 41
12 Clamp the replacement panel in position on the
vehicle and check the door opening dimensions, refer
to Section 3A, 3 Body Dimensions. Adjust po sition as
required.
Figure 7A – 42
Body Side, Regular Cab Page 7A–24
Page 7A–24
13 Plug weld (1) the top of the pillar to the manufactured
reinforcement, then MIG butt weld (2) the two sections
together.
Figure 7A – 43
14 Plug weld (1) the new panel in the rocker panel region,
then MIG butt weld (2) the two sections together.
Figure 7A – 44
15 Gaining access through the removed sectio n of inner
panel, MIG butt weld (1) the reinforcement panel
together.
16 Butt weld the removed access panel (2) in position.
Replace the spot welds with the same number that
was removed.
Figure 7A – 45
Body Side, Regular Cab Page 7A–25
Page 7A–25
17 Spot weld (1) the pillar along the door op ening flange.
18 Spot weld (2) the flange beneath the rocker pan el,
attaching the new panel to the inner rocker panel.
Figure 7A – 46
19 Spot weld (1) the pillar along the windshield opening
flange.
Figure 7A – 47
20 Spot or plug weld the door opening frame assembly
(1) to the hinge pillar inner panel assembly (2) at the
base of the hinge pillar.
Figure 7B – 48
Body Side, Regular Cab Page 7A–26
Page 7A–26
21 Spot or plug weld the door opening frame assembly to
the inner rocker panel and to the hinge pillar inner
panel assembly.
NOTE
If the sheet metal was modified to allow access
to these welds, it should be repaired to its
original configuration.
Figure 7A – 49
22 Gaining access through the section of removed in ner
rocker panel, MIG butt weld (1) the new section of
rocker panel reinforcement to the existing section.
23 Replace the removed section of inner rocker panel (2)
by MIG butt welding it in place and spot welding it
along the door opening flange. Replace the spot welds
with the same number of as were removed.
24 Install the door hinges, refer to
Section 8 Doors, Liftgate & Endgate in the M Y 2003 VY
and V2 Service Information Supplement, Body
Structure Repair.
25 Replace other adjoining removed pane ls as required,
refer to the relevant Section in this Supplement.
26 Refinish and paint panels and other components as
required. Refer to Section 3, 1.3 Paint Refinishing in
the MY 2003 VY and V2 Series Service Inform ation
Supplement, Body Structure Repair.
Figure 7A – 50
27 Apply Joint Sealer (Item 3) as required. Refer to Section 3A, 5 Body Sealing, Adhesives and Deadeners.
28 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.
29 Install the dash panel retaining bolt throu gh the hinge pillar and tighten to the specified torque.
Dash panel retaining b olt
torque specification.........................................35.0 – 45.0 Nm
30 Replace the windshield, refer to Section 1A6 Stationary Glass in the MY 2004 Regular C ab and Crew Cab Service
Information.
31 Insert Cavity Foam into the hinge pillar as required, refer to Section 2, 2.10 Cavity Foam in the MY 2003 VY and V2
Series Service Information Supplement, Body Structure Repair.
32 Reinstall the front door assembly, refer to refer to Section 8 Doors, Liftgate & Endgate in the MY 2003 VY and V2
Series Service Information Supplement, Body Structure Repair.
33 Install the remaining components as described in the appropriate Section of the MY 2004 Regular Cab and Crew
Cab Service Information.
Body Side, Regular Cab Page 7A–27
Page 7A–27
2.5 Door Opening Frame Assembly – Partial
Replace, Centre Pillar
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2004 Regular Cab and Crew Cab Service Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the appropriate structural s ections
of the vehicle on safety stands. Secure a suitable tool
between the front door openi ng flanges to maintain
alignment.
3 Remove the rear quarter panel, refer to
2.1 Rear Quarter Panel – Replace.
4 Remove the rear quarter panel reinforcement, refer to
2.2 Rear Quarter Panel Reinforcement – Replace.
Figure 7A – 51
5 Cut the door opening frame a ssembly (1) as shown.
NOTE
The upper cut is just below the recess and the
lower cut is approximately level with the centre
pillar upper reinforcement.
6 Spot cut the two welds attaching door opening frame
assembly to the centre pillar reinforcement.
7 Spot cut the welds attaching the door openin g frame
assembly to the quarter panel inner assembly.
Figure 7A – 52
Body Side, Regular Cab Page 7A–28
Page 7A–28
8 Cut through the rocker panel section of the door
opening frame assembly. The cut point (1) sh ould be
approximately 100 mm from the dimple (2) on the
flange. Cut through both the outer pane l and the
reinforcement panel.
9 Spot cut the welds attaching the underbod y jacking
locator (1) and remove, refer to Figure 7A – 53.
10 Spot cut the welds attaching the front and rear sides of
the door opening frame assembly to the quarter panel
inner assembly.
NOTE
The number of welds will vary depending on the
cut locations.
11 Spot cut the 12 welds attaching lower edge of the
quarter panel inner assembly to the door opening
frame.
12 Spot cut the four welds attaching the centre pillar
upper reinforcement to the centre pillar reinforcement.
13 Remove the centre pillar section from the vehicle.
14 Repair any damage to adjacent parts as required.
Figure 7A – 53
Figure 7A – 54
Body Side, Regular Cab Page 7A–29
Page 7A–29
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment 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 Cut the replacement door opening frame assembly through rocker section. Accurately measure the position of cuts
to match the removed panel section.
2 Cut the replacement door opening frame assembly
below the recess to match the removed section from
the vehicle (1).
NOTE
Cut through the outer panel onl y.
3 Make a second cut approximately level with the centre
pillar upper reinforcement (2).
NOTE
Cut through the flange and front side ONLY.
4 Cut the required spot welds and carefull y bend the
outer panel down to expose the spot welds attaching
the centre pillar upper reinforc ement to the centre
pillar reinforcement.
Figure 7A – 55
5 On the replacement panel, spot cut the five welds
attaching the centre pillar lower section to the centre
pillar upper reinforcement and remove the s ection.
Figure 7A – 56
Body Side, Regular Cab Page 7A–30
Page 7A–30
6 Remove a section of inner rocker panel (1), cut 50 mm
each side of the cut in the rocker panel (2). This all ows
access for welding the rocker panel reinf orcement.
Figure 7A – 57
7 Cut two sections from surplus rocker panel pieces, or
manufacture new sections (1), each ap proximately
100 mm in length.
8 Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to Section
3A, 5 Body Sealing, Adhesives and Dead eners.
9 Clamp these sections firmly behi nd both the cut faces
of rocker panel on the vehicle and spot or plug weld in
place. Perform the welds at a maximum spacing of 35
mm apart.
10 Mark the new panel with drilling locations in
preparation for plug welding where required. Drill holes
as marked.
11 Prepare the mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to Section
3A, 5 Body Sealing, Adhesives and Dead eners.
Figure 7A – 58
12 Install the replacement panel i n position, sliding the
centre pillar reinforcement (1) and the centre pillar
lower reinforcement (2) behind the centre pillar upper
reinforcement (3), until the front edge of the lo wer
reinforcement butts against the front edge of the upper
reinforcement.
13 Manipulate the rocker panel section in position,
inserting the front first, then the rear and clamp the
assembly in place.
Figure 7A – 59
Body Side, Regular Cab Page 7A–31
Page 7A–31
14 Plug weld the centre pillar upper reinforcement to the
centre pillar lower reinforcement, two places and the
centre pillar reinforcement two places.
Figure 7A – 60
15 Bend the outer panel back in position and MIG butt
weld the sections together as shown (1 and 2).
16 Plug weld the outer panel, centre pillar up per
reinforcement and centre pillar reinforcement two
places.
17 Plug weld (1) the front and rear sides of the door
opening frame assembly to the quarter panel inner
assembly, refer to Figure 7A – 62.
NOTE
The number of welds will vary depending on the
cut locations.
18 Plug weld (2) the front and rear sides of the door
opening frame assembly to the rocker panel
reinforcement.
Figure 7A – 61
19 Plug weld on the underside of the rocker panel, the centre pillar section to the quarter panel inner ass embly and
the rocker panel, refer to Figure 7A – 62.
20 Plug weld the lower edge of the qu arter panel inner assembly to the door opening frame.
21 MIG butt weld (3) each join across the rocker panel.
22 Plug weld the underbody jacking locator (4) in place.
Body Side, Regular Cab Page 7A–32
Page 7A–32
Figure 7A – 62
23 Dress the welds by grinding or sanding, ensuring sufficient material r emai ns to guarantee the strength of the weld.
Finish the area using an appropriate technique.
24 Replace the adjoining removed panels as required, refer to the relevant Section in this Supplement.
25 Refinish and paint panels and other components as required. Refer to Section 3, 1.3 Paint Refinishing in the MY
2003 VY and V2 Series Service Information Supplement, Body Structure Repair.
26 Apply Joint Sealer (Item 3) as required. Refer to Section 3A, 5 Body Sealing, Adhesives and Deadeners.
27 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.
28 Insert Cavity Foam into the centre pillar as required, refer to Section 2, 10.1 Cav ity Foam in the MY 2003 VY and
V2 Series Service Information Supplement, Body Structure Repair.
29 Install the remaining components as described in the appropriate Section of the MY 2004 Regular Cab and Crew
Cab Service Information.
Body Side, Regular Cab Page 7A–33
Page 7A–33
2.6 Quarter Panel Inner Assembly – Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of th e MY
2004 Regular Cab and Crew Cab Service Information.
2 Remove the rear quarter panel, refer to
2.1 Rear Quarter Panel – Replace.
3 Remove the rear quarter panel reinforcement, refer to
2.2 Rear Quarter Panel Reinforcement – Replace.
4 Remove the door opening frame assembly, refer to
2.3 Door Opening Frame Assembly – Replace.
Figure 7A – 63
5 Grind off the MIG weld (1) attaching the quarter panel
inner assembly to the inner rocker panel assembly.
6 Spot cut the welds attaching the quarter panel inner
assembly to the rear lower body panel and the inner
rocker panel assembly.
Figure 7A – 64
Body Side, Regular Cab Page 7A–34
Page 7A–34
7 Spot cut the welds attaching the quarter panel inner
assembly to the inner rocker panel.
8 Grind the four MIG welds (1) from the inside of the
quarter panel inner assembly, joining the inner rocker
panel.
Figure 7A – 65
9 Spot cut the welds attaching the quarter panel inner
assembly to the quarter panel inner extension.
Figure 7A – 66
10 Spot cut the welds attaching the door openin g frame
assembly to the roof rear header panel.
11 Remove the quarter panel inner assembly and repair
any damage to adjacent parts as required.
12 Check and rectify the alignme nt of the bod y as
required, refer to Section 3A, 3 Body Dimensions.
Figure 7A – 67
Body Side, Regular Cab Page 7A–35
Page 7A–35
Replace
NOTE
Spot welding is the preferred method for
attaching of panels and should be used whenever
possible. Where the spot welding equipment 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 Mark the new panel and drill holes in preparation for plug welding where required.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3A,
5 Body Sealing, Adhesives and Dea de ners.
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3A, 5 Body Sealing, Adhesives & Deadeners.
4 Clamp the new panel in position on the vehicle.
5 Plug or spot weld the door opening frame assembly to
the roof rear header panel.
Figure 7A – 68
6 Plug or spot weld the quarter panel inner assembly to
the quarter panel inner extension.
Figure 7A – 69
Body Side, Regular Cab Page 7A–36
Page 7A–36
7 Plug or spot weld the quarter panel inner assembly to
the inner rocker panel.
8 MIG weld four places, the quarter panel inner
assembly to the inner rocker panel (1).
Figure 7A – 70
9 Plug or spot weld the quarter panel inner assembly to
the rear lower body pan el and the inner rocker panel
assembly.
10 MIG weld (1) the quarter panel inner assembl y to the
inner rocker panel assembly.
11 Clean up welds and prime any bare metal.
12 Replace the door opening fra me assembly, refer to
2.3 Door Opening Frame Assembly – Replace.
13 Replace the rear quarter panel reinforceme nt, refer to
2.2 Rear Quarter Panel Reinforcement – Replace.
14 Replace rear quarter panel, refer to
2.1 Rear Quarter Panel – Replace.
15 Replace other adjoining removed pane ls as required,
refer to the relevant Section in this Supplement.
16 Refinish and paint panels and other components as
required. Refer to Section 3, 1.3 Paint Refinishing in
the MY 2003 VY and V2 Series Service Inform ation
Supplement, Body Structure Repair.
Figure 7A – 71
17 Apply Joint Sealer (Item 3) as required. Refer to Section 3A, 5 Body Sealing, Adhesives and Deadeners.
18 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.
19 Apply Spray-on Dea de ner (Item 7) to the wheel side of the rear wheelhouse, refer to Section 3A,
5 Body Sealing, Adhesives and Dea de ners.
20 Install the remaining components as described in the appropriate Section of the MY 2004 Regular Cab and Crew
Cab Service Information.