Roof Page 9–1

Page 9–1

Section 9

Roof

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 Crew Cab Roof Components ................................................................................................................................ 2

2 Service Operations – Crew Cab............................................................................................................4

2.1 Roof Panel – Replace ............................................................................................................................................ 4

Remove................................................................................................................................................................... 4

Replace................................................................................................................................................................... 6

2.2 Roof Front Header Panel – Replace ..................................................................................................................... 9

2.3 Roof Bow Panel – Replace.................................................................................................................................. 10

2.4 Roof Rear Header Outer Panel – Replace.......................................................................................................... 11

Remove................................................................................................................................................................. 11

Replace................................................................................................................................................................. 11

2.5 Roof Rear Header Inner Panel – Replace........................................................................................................... 13

Remove................................................................................................................................................................. 13

Roof Page 9–2

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1 General Information

With the following exceptions, VY Regular Cab and Crew Cab roof information carries over from MY 2003 VY Series

vehicles.

Crew Cab:

• Roof components

• Roof panel

• Roof rear header inner and outer pane ls

The Roof structure fitted to VY Regular Cab vehicles carries over from MY 2003 VY Utility vehicles.

For information not contained within this Section, refer to Section 9 Roof in the MY 2003 VY and V2 Series Service

Information Supplement, Body Structure Repair. Removal of trim and bolt-on components is not covered. Reference

must be made to the appropriate Sections in the MY 2004 Regular Cab and Crew Cab Service Information.

The roof panel is both spot welded and glued in place with structural adhesive. Heating or other normal means cannot

soften this adhesive and the panel can o nly be removed by cutting and/or grinding.

NOTE

• When repairing the roof 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 Crew Cab vehicles. Refer to

Section 3B, 5 Body Sealing, Adhesives and

Deadeners and 6 Cavity Wax for details of the

correct materials and their commercially

available equivalents.

1.1 Crew Cab Roof Components

The shaded components in Figure 9 – 1 are those dealt with

in this Section.

The components and assemblies shown in Figure 9 – 2 are

the parts serviced for VY Crew Cab vehicles which form the

basis of the repair procedures in this Section. For a detailed

view of the body components, refer to

Section 3B Body Construction, Crew Cab.

NOTE

Always refer to an Authorised Dealer for spare

parts availability configurations.

Figure 9 – 1

Roof Page 9–3

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Figure 9 – 2

Legend

1 Roof Front Header Panel

2 Roof Panel

3 Roof Bow Panel

4 Roof Rear Header Inner Panel

5 Roof Rear Header Outer Panel

Roof Page 9–4

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2 Service Operations – Crew Cab

2.1 Roof Panel – Replace

Remove

1 Remove the adjacent trim and components as described in the appropriate Section of the MY 2004 VY Regular

Cab and Crew Cab Service Information.

2 Remove the adjacent bolt-on panels and components as described in the appropriate Section of the MY 2004 VY

Regular Cab and Crew Cab S ervice Information.

3 Remove the windshield and rear window, refer to Section 1A6 Stationary Windows in the MY 2004 VY Regular Cab

and Crew Cab Service Information.

4 Remove other adjacent pane ls as required, refer to the relevant Section in this Supplement.

5 Spot cut the welds attaching the roof panel to the roof

front header panel.

6 Using a cutting tool such as an air chisel or a ngle

grinder, cut through the roof panel alo ng the rear of

the roof, refer to Figure 9 – 4.

NOTE

As the roof panel is attached with structural

adhesive (1) to the roof rear head er outer panel,

it cannot be removed by simply spot cutting the

welds.

Figure 9 – 3

Figure 9 – 4

Roof Page 9–5

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7 Using a cutting tool such as an air chisel or a ngle

grinder, cut through the roof panel along the side of

the roof channel.

NOTE

As the roof panel is attached with structural

adhesive (1) to the door opening frame

assembly, it cannot be removed by simply spot

cutting the welds.

If the roof front header panel, roof bow panel and

roof rear header inner a nd ou ter pa nels ar e t o b e

retained, take care not to cut them off with the

roof panel. Alternatively, if on e or more are to be

replaced, it is easier to cut off those being

replaced along with the roof panel.

Figure 9 – 5

8 Use a heat gun to soften the Anti-flutter adhesive

between the roof front header panel a nd roof bow

panel by heating the areas sh own.

Figure 9 – 6

9 Cut through the softened adhesive between the roof

panel and roof front header panel, roof bow panel and

roof rear panel using a suitable tool.

10 Remove the roof panel from the vehicle.

Figure 9 – 7

Roof Page 9–6

Page 9–6

11 Using an angle grind er, air chi s el or other suitable tool,

remove the remaining strip of roof panel from the door

opening frame assembly, along with the adhesive

beneath the strip.

Figure 9 – 8

12 Using an angle grind er, air chi s el or other suitable tool,

remove the remaining strip of roof panel from the rear

roof header outer panel, along with the adhesive

beneath the strip.

13 Repair any damage to adjacent parts.

14 Check and rectify the alignme nt of the bod y as

required, refer to Section 3B, 3 Body Dimensions.

Figure 9 – 9

Replace

NOTE

When welding a relatively flat panel such as the

roof panel, due care must be taken to minimise

the heat absorbed by the pan el, which could lead

to panel distortion.

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.

Roof Page 9–7

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1 Clean the remaining Anti-flutter adhesive fro m the surfaces of the roof front header panel and, roof bo w panel.

2 Prepare the mating surface areas for welding. Dress the channel flange area, the roof fro nt head er panel, roof bow

panel and roof rear inner and outer panels as required so they are flat and free from imperfections.

3 As required, mark the new panel with drilling locations in preparation for pl ug welding. Drill holes as requ ired.

4 Apply Structural Adhesive (Item 6), refer to Section 3B, 5 Body Sealing, Adhesives & Deadeners, to the door

opening frame assembly flange (1) and re ar roof header outer panel flange (2), refer to Figure 9 – 10.

Figure 9 – 10

5 Apply a bead of Anti-flutter Adhesiv e (Item 5) to the full

length of the groove in the roof front header panel.

Refer to Section 3B, 5 Body Sealing, Adhesives &

Deadeners.

6 Apply two full length bea ds of Anti-flutter adhesive to

the grooves in the roof bow panel, refer to Section 3B,

5 Body Sealing, Adhesives & Dea deners.

7 Position the roof panel on the vehicle and clamp in

place.

Figure 9 – 11

8 Spot or plug weld the roof panel to the door opening

frame on both sides of the vehicle.

NOTE

In some cases it may be advantageous to begin

welding from the middle of the run and weld

alternatively to the front and rear. This may

reduce panel distortion.

Figure 9 – 12

Roof Page 9–8

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9 Spot or plug weld the roof panel to the roof front

header panel and the roof rear header inner and outer

panels.

10 Refinish and paint panels and other components as

required. Refer to Section 3, 1.3 Paint Refinishing in

the MY2003 VY and V2 Servi ce Information

Supplement, Body Structure Repair.

11 Apply Joint Sealer (Item 3) as required. Refer to

Section 3B, 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 3B, 6 Cavity Wax.

13 Replace the windshield and rear window, refer to

Section 1A6 Stationary Glass in the MY 2004 VY

Regular Cab and Crew Cab S ervice Information.

14 Install the remaining components as described in the

appropriate Section of the MY 2004 VY Regu lar Cab

and Crew Cab Service Information. Figure 9 – 13

Roof Page 9–9

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2.2 Roof Front Header Panel – Replace

Following removal of the roof panel, as required spot cut the welds attaching the roof front header panel as shown in the

following diagram.

When installing a roof front header p an el, eit her spot weld the part to the vehicle or mark and drill the new part with holes

in preparation for plug welding. The number of spot or plug welds must match the number shown in the appropriate

diagram.

Before fitting the part, prepare the mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to

Section 3B, 5 Body Sealing, Adhesives & Deadeners.

1 The two spot welds (1) are removed with the roof

panel.

2 Remove the five spot welds (2) from each side of the

vehicle to remove the roof front header panel.

3 Remove the roof front header panel from the vehicle

and repair any dama ge to adjacent parts as required.

4 Check and rectify the alignme nt of the bod y as

required, refer to Section 3B, 3 Body Dimensions.

Figure 9 – 14

Roof Page 9–10

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2.3 Roof Bow Panel – Replace

Following removal of the roof panel, as required spot cut the welds attaching the roof bow panels as sh own in the

following diagrams.

When installing a roof bow panel, either spot weld the part to the vehicle or mark and drill the new part with holes in

preparation for plug welding. The number of spot or plug welds must match the number sho wn in the appropriate

diagram.

Before fitting the part, prepare the mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to

Section 3B, 5 Body Sealing, Adhesives & Deadeners.

1 The spot weld (1) is removed with the roof panel.

2 Remove the two spot welds (2) from each side of the

vehicle to remove the roof bow panel.

3 Remove the roof bow panel from the vehic le and

repair any damage to adjacent parts as required.

4 Check and rectify the alignme nt of the bod y as

required, refer to Section 3B, 3 Body Dimensions.

Figure 9 – 15

Roof Page 9–11

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2.4 Roof Rear Header Outer Panel – Replace

Remove

1 Remove the adjacent bolt-on panels a nd components as described in the appropri ate Se ction of the MY 2004

Regular Cab and Crew Cab S ervice Information.

2 Remove the roof panel, refer to 2.1 Roof Panel – Replace.

3 Using a cutting tool such as an air chisel or a ngle grinder, cut through the roof rear header outer panel in from the

forward flange and in from each end (1), refer to Figure 9 – 16.

Figure 9 – 16

4 Spot cut the welds, three places, attaching the roof rear header outer panel to the roof rear head er inner panel and

quarter panel inner assembly. Repeat for the opposite side of the vehicle.

5 Spot cut the welds attaching the roof rear header outer panel to the roof re ar header inner panel.

6 Remove the roof rear header outer pane l from the vehicle.

7 Using a cutting tool such as an air chisel or a ngle grinder, remove the remaining strip of roof rear header outer

panel, along with the adhesive beneath the strip.

8 Repair any damage to adjacent parts as required.

9 Check and rectify the alignme nt of the body as required, refer to Section 3B, 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 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.

Roof Page 9–12

Page 9–12

1 Prepare the mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3 B,

5 Body Sealing, Adhesives & Dea deners.

2 Apply Structural Adhesive (1, Item 6), refer to Section 3B, 5 Body Sealing, Adhesives and Deadeners, refer to

Figure 9 – 17.

3 Clamp the new panel in position on the vehicle.

4 Plug or spot weld on each side of the vehicle , attaching the roof rear header outer panel to the quarter panel inn er

assembly and roof rear heade r inner panel.

Figure 9 – 17

5 Refinish and paint panels and other components as required. Refer to Section 3, 1.3 Paint Refinishing in the

MY2003 VY and V2 Service Information Supplement, Body Structure Repair.

6 Apply Joint Sealer (Item 3) as required, refer to Section 3B, 5 Body Sealing, Adhesives and Deadeners.

7 Apply Cavity Wax (Item 8) as required to the inside of any box sections or areas inaccessible to paint, refer to

Section 3B, 6 Cavity Wax.

8 Reinstall the remaining com ponents as described in the appropriate Section in the MY 2004 VY Regular Cab and

Crew Cab Service Information.

Roof Page 9–13

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2.5 Roof Rear Header Inner Panel – Replace

Remove

Following removal of the roof panel, as required spot cut the welds attaching the roof rear header inner panel as shown

in the following diagrams.

When installing a roof rear header inner panel, either spot weld the part to the vehicle or mark and drill the new part with

holes in preparation for plug welding. The number of spot or plug welds must match the number shown in the appropriate

diagram.

Before fitting the part, prepare the mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to

Section 3B, 5 Body Sealing, Adhesives & Deadeners.

1 Spot cut the welds from each side of the vehicle

attaching the roof rear heade r inner panel.

2 Remove the roof rear header inner pan el from the

vehicle and repair any damag e to adjacent parts as

required.

3 Check and rectify the alignme nt of the bod y as

required, refer to Section 3B, 3 Body Dimensions.

Figure 9 – 18