Body Rear, Crew Cab Page 10B–1
Page 10B–1
Section 10B
Body Rear, Crew 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 workshop 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 Rear Components........................................................................................................................................ 2
2 Service Operations.................................................................................................................................3
2.1 Rear Body Lower Panel Assembly – Replace ..................................................................................................... 3
Remove................................................................................................................................................................... 3
Replace................................................................................................................................................................... 4
2.2 Rear Body Upper Outer Panel Assembly – Replace........................................................................................... 6
Remove................................................................................................................................................................... 6
Replace................................................................................................................................................................... 7
2.3 Rear Body Upper Inner Panel Assembly – Replace............................................................................................ 8
Remove................................................................................................................................................................... 8
Replace................................................................................................................................................................... 8
Body Rear, Crew Cab Page 10B–2
Page 10B–2
1 General Information
This Section describes replacement procedures for the rear components o f the VY Crew Cab body struc t ure. Removal of
bolt-on and mechanical components is not covered. Reference must be made to the appropriate Sectio ns in the MY
2004 VY Regular Cab and Cr ew Cab Service Information.
For removal of the rear subframe assembly refer to Section 1B, 2.2 Subframe Assembly in the MY 2004 VY Regular Cab
and Crew Cab Service Information.
NOTE
• When repairing the rear 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 &
Deadeners and 6 Cavity Wax for details of the
correct materials and their commercially
available equivalents.
1.1 Body Rear Components
The shaded components in Figure 10B – 1 are those dealt
with in this Section.
The components and assemblies shown in Figure 10B – 2
are the parts serviced for VY Crew Cab vehicles which form
the basis of the repair procedures in this Secti on. F or 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 10B – 1
Figure 10B – 2
Legend
1 Rear Body Upper Inner Panel Assembly
2 Rear Body Upper Outer Panel Assembly 3 Rear Body Lower Panel Assembly
Body Rear, Crew Cab Page 10B–3
Page 10B–3
2 Service Operations
2.1 Rear Body Lower 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.
Figure 10B – 3
2 Spot cut the welds, eight places on each side,
attaching the lower panel assembly to the rear body
lower panel and the front floor panel extension
assembly.
3 Spot cut the welds, three places, attaching the lower
panel assembly to the front floor extension.
Figure 10B – 4
Body Rear, Crew Cab Page 10B–4
Page 10B–4
4 Grind off the MIG weld (1), five places, attaching the
lower panel assembly to the rear body upper outer
reinforcement panel assembly.
5 Spot cut the welds attaching the lower panel assembly
to the rear upper outer panel assembl y.
6 Remove the lower panel from the vehicl e and repair
any damage to adjacent parts as required.
7 Check and rectify the alignme nt of the bod y as
required, refer to Section 3B, 3 Body Dimensions.
Figure 10B – 5
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 plug welding. Drill holes as required.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3B,
5 Body Sealing, Adhesives & Dea deners.
3 Clamp the rear body lower panel assembly in position on the vehic le.
4 MIG weld (1), five places, the lower panel assembly to
the rear body upper outer panel assem bl y.
5 Plug or spot weld the lower panel assembly to the rear
upper outer panel assembly.
Figure 10B – 6
Body Rear, Crew Cab Page 10B–5
Page 10B–5
6 Spot or plug weld the lower panel assembly to the
front floor extension.
7 Spot or plug weld, eight places on each side, the lower
panel assembly to the rear body lower panel and the
front floor panel extension assembly.
8 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.
9 Apply joint sealer (Item 3) as required. Refer to
Section 3B, 5 Body Sealing, Adhesives & Deadeners.
10 Apply cavity wax (Item 8) as requ ired to the inside of
any box sections or areas inaccessible to paint, refer
to Section 3B, 6 Cavity Wax.
11 Install the remaining components as described in the
appropriate Section of the MY 2004 VY Regu lar Cab
and Crew Cab Service Information. Figure 10B – 7
Body Rear, Crew Cab Page 10B–6
Page 10B–6
2.2 Rear Body Upper Outer 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 end lower panel, refer to
2.1 Rear Body Lower Panel Assembly – Replace.
Figure 10B – 8
3 Grind off the MIG welds (1) on each side of the vehicle, attaching the rear body upper outer pane l assembly to the
quarter panel inner, refer to Figure 10B – 9.
4 Spot cut the welds on each side of the vehicle, attachin g the upper and lower flanges of the rear body upper outer
panel assembly to the rear body upper inner panel assembly and the side body inner panel.
NOTE
If the rear body upper inner panel assembly is
also to be removed, spot cut and grind off only
the relevant welds.
Figure 10B – 9
5 Remove the outer reinforcement pane l assembly then repair any damage to adjacent parts as required.
6 Check and rectify the alignme nt of the bod y as required, refer to Section 3B, 3 Body Dimensi ons.
Body Rear, Crew Cab Page 10B–7
Page 10B–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 plug welding. Drill holes as required.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3B,
5 Body Sealing, Adhesives & Dea deners.
3 Clamp the rear body upper o uter panel assembly in position on the vehicle.
4 Spot or plug weld on each side of the vehic le , the upper and lower flanges of the rear body upper outer panel
assembly to the rear body upper inner pane l assembly and the side body inner panel, refer to F igure 10B – 10.
5 MIG weld (1), the rear body upper outer panel assembly to the quarter panel inner on each side of the vehicle.
Figure 10B – 10
6 Install the rear body lower panel assembly, refer to 2.1 Rear Body Lower Panel Assembly – Replace.
7 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.
8 Apply Joint Sealer (Item 3) as required. Refer to Section 3B, 5 Body Sealing, Adhesives & Deadeners.
9 Apply Cavity Wax (Item 8) as required to the inside of any box sections or areas in accessible to paint, refer to
Section 3B, 6 Cavity Wax.
10 Install the remaining compon ents as described in the appropriate Secti on of the MY 2004 VY Regular Cab and
Crew Cab Service Information.
Body Rear, Crew Cab Page 10B–8
Page 10B–8
2.3 Rear Body Upper Inner 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 body lower panel assembly, refer to
2.1 Rear Body Lower Panel Assembly – Replace.
3 Remove the rear body upper outer panel assembly,
refer to 2.2 Rear Body Upper Outer Panel Assembly –
Replace.
Figure 10B – 11
4 From inside the vehicle, spot cut the welds o n each
side of the vehicle, attaching the rear body upper i nner
panel to the side body inner p anel.
NOTE
Some of these welds may have already been
removed with the rear body upper outer panel
assembly.
5 Remove the rear body upper inner panel assembly
from the vehicle and repair any damage to adjacent
parts as required.
6 Check and rectify the alignme nt of the bod y as
required, refer to Section 3B, 3 Body Dimensions.
Figure 10B – 12
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 plug welding. Drill holes as required.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as required, refer to Section 3B,
5 Body Sealing, Adhesives & Dea deners.
3 Clamp the rear body upper i nner panel in position on the vehicle.
Body Rear, Crew Cab Page 10B–9
Page 10B–9
4 From inside the vehicle, spot or plug weld on each
side of the vehicle, the rear body upper inner panel to
the side body inner panel.
5 Clean up the welds and a pply primer to any bare
metal.
6 Install the rear body upper outer panel assembly, refer
to 2.2 Rear Body Upper Outer Panel Assembly –
Replace.
7 Install the rear body lower panel assembly, refer to
2.1 Rear Body Lower Panel Assembly – Replace.
8 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.
9 Apply Joint Sealer (Item 3) as required. Refer to
Section 3B, 5 Body Sealing, Adhesives & Deadeners.
10 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.
11 Install the remaining components as described in the
appropriate Section of the MY 2004 VY Regu lar Cab
and Crew Cab Service Information.
Figure 10B – 13