6F Cabin Floor – Crew Cab Page 6F–1
Page 6F–1
Section 6F
Cabin Floor – Crew Cab
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to Section 2
Precautions in this Supplement and Section 00 Warnings, Cautions and Notes in the MY2005 VZ Service
Information for correct workshop practices with regard to safety and/or property damage.
The structure of the body shell has been
developed using complex design and
development 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 here 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................................................................................................................................................................... 6
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 Front Floor Panel Extension Assembly – Replace............................................................................................ 15
Remove................................................................................................................................................................. 15
Replace................................................................................................................................................................. 16
2.5 Front Floor Panel Assembly – Replace.............................................................................................................. 18
Remove................................................................................................................................................................. 18
Replace................................................................................................................................................................. 20
2.6 Transmission Support Bracket, AWD – Replace............................................................................................... 22
Remove................................................................................................................................................................. 22
Replace................................................................................................................................................................. 23
6F Cabin Floor – Crew Cab Page 6F–2
Page 6F–2
1 General Information
With the following exceptions the Re gular Cab cabin floor information carries over from Sedan vehicles. For information
not covered in this Section, refer to Section 6A Cabin Floor – Sedan, Wagon, Coupe and AWD W agon .
• Cabin floor components
• Inner rocker panel assembly
• Rear body lower panel ass embly
• Rear body lower panel
• Front floor panel extension
• Front floor panel assembly
• Transmission Support Bracket, AWD
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 of the MY2005 VZ 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, refer to Section 3F Body
Construction – Crew Cab 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 6F – 2 are the servicea b le parts that form the basis
of the repair procedures in this Section.
For a detailed view of the body components,
refer to Section 3F Body Construction – Crew Cab .
NOTE
Always refer to an Authorised Retailer for spare
parts availability configurations.
Figure 6F – 1
6F Cabin Floor – Crew Cab Page 6F–3
Page 6F–3
Figure 6F – 2
Legend
1 Inner Rocker Panel Assembly, Left-hand / Right-hand
2 Seat Inner Bracket Assembly*
3 Seat Outer Bracket Assembly, Left-hand/ Right-hand*
4 Front Floor Panel Assembly
5 Transmission Support Bracket, Right-hand/ Left-hand # *
6 Transmission Support Bracket, Left-hand (AWD only)
7 Front Floor Panel Extension*
8 Propeller Shaft Hanger Assembly*
9 Rear Seatbelt Anchor Plate Assembly, three places*
10 Floor Panel Plate Assembly, two each Left-hand/ Right-
hand*
11 Rear Lower Body Panel Assembly, Left-hand/ Right-hand
12 Rear Lower Body Panel
13 Front Floor Panel Extension Assembly
* For replacement procedures refer to Section 6A Cabin Floor – Sedan, W agon, Coupe and AWD Wagon.
# Right-hand side only for AWD vehicles.
6F Cabin Floor – Crew Cab Page 6F–4
Page 6F–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 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 frame assembly
and quarter panel inner ass embly,
refer to Section 7F Body Side – Crew Cab.
4 Remove other adjacent pane ls as required, refer to the
relevant Section in this Supplement.
Figure 6F – 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 6F – 5.
Figure 6F – 4
Figure 6F – 5
7 Grind off the MIG welds (1) attaching the inner rocker panel assembl y to the front floor panel extension,
refer to Figure 6F – 6.
8 Spot cut the welds attaching the inner rocker panel assembly to the rear body lower panel, front floor panel
extension and the rear body lower panel assembly.
6F Cabin Floor – Crew Cab Page 6F–5
Page 6F–5
Figure 6F – 6
9 Spot cut the welds attaching the inner rocker panel
assembly to the centre crossmember (A), and front
floor panel support (B).
10 Remove the inner rocker panel assembl y from the
vehicle and repair any damag e to adjacent panels as
required.
11 Check and rectify the alignme nt of
the body as requir ed,
refer to Section 3F Body Construction – Crew Cab .
Figure 6F – 7
6F Cabin Floor – Crew Cab Page 6F–6
Page 6F–6
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 requir ed,
refer to Section 3F Body Construction – Crew Cab .
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3F Body Construction – Crew Cab .
4 Clamp the inner rocker panel assembly in position, noting to ensure it fits behind the hinge pill ar inner assembly.
5 Spot or plug weld the inner rocker panel assembly to
the centre crossmember (A) and front floor panel
support (B).
6 Spot or plug weld the inner rocker panel assembly to
the rear body lower panel, front floor panel extension
and the rear body lower panel assembly,
refer to Figure 6F – 9.
7 MIG weld (1) the inner rocker panel assembly to the
rear front floor panel extension.
Figure 6F – 8
Figure 6F – 9
8 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 6F – 10.
6F Cabin Floor – Crew Cab Page 6F–7
Page 6F–7
Figure 6F – 10
9 Make six MIG welds (1) to attach inner rocker panel
assembly to the hinge pillar inner assembly.
10 Replace the adjoining removed 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 Body Construction.
12 Apply Joint Sealer (Item 3) as required.
refer to Section 3F Body Construction – Crew Cab .
13 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3F Body Construction – Crew Cab .
Figure 6F – 11
14 Reinstall the remaining bolt-on panels and components as required, refer to the appropriate Section of the MY2005
VZ Service Information.
6F Cabin Floor – Crew Cab Page 6F–8
Page 6F–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 MY2005
VZ 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 6F – 12
4 Spot cut the welds attaching the rear body lower panel
assembly to the rear body lower panel.
Figure 6F – 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 6F – 14
6F Cabin Floor – Crew Cab Page 6F–9
Page 6F–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 6F – 16.
Figure 6F – 15
Figure 6F – 16
8 Remove the rear body lower panel assembly from the vehicle and repair any damage to adjacent panels as
required.
9 Check and rectify the alignme nt of the body as required, ref er to Section 3 F Body Construction – Cre w Cab .
6F Cabin Floor – Crew Cab Page 6F–10
Page 6F–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 plug welding. Drill holes as required.
2 Prepare all mating surfaces and treat with Weld Through Primer (Item 1) as requir ed,
refer to Section 3F Body Construction – Crew Cab .
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3F Body Construction – Crew Cab .
4 Spot or plug weld the rear body lower panel assembly to the rear body lower panel and the front floor panel
extension, refer to Figure 6F – 17.
Figure 6F – 17
6F Cabin Floor – Crew Cab Page 6F–11
Page 6F–11
5 Spot or plug weld the rear body lower panel assembly
to the inner rocker panel asse mbly.
Figure 6F – 18
6 Spot or plug weld the rear body lower panel assembly
to the front floor panel extension.
Figure 6F – 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
required. refer to Section 3 Body Construction.
10 Apply Joint Sealer (Item 3) as required.
refer to Section 3F Body Construction – Crew Cab .
11 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3F Body Construction – Crew Cab .
12 Reinstall the remaining bolt-on panels and
components as required, refer to the appropriate
Section of the MY2005 VZ Service Information.
Figure 6F – 20
6F Cabin Floor – Crew Cab Page 6F–12
Page 6F–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 MY2005
VZ 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 10F Body Rear – Crew Cab.
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 6F – 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 extension an d the inner rocker
panel assembly, refer to Figure 6F – 23.
Figure 6F – 22
6F Cabin Floor – Crew Cab Page 6F–13
Page 6F–13
Figure 6F – 23
8 Remove the rear body lower panel from the vehicle and repair any damage to adjacent panels as required.
9 Check and rectify the alignme nt of the body as required, ref er to Section 3 F Body Construction – Cre w Cab .
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 requir ed,
refer to Section 3F Body Construction – Crew Cab .
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3F Body Construction – Crew Cab .
4 Plug or spot weld the rear body lower panel to the front floor panel extens ion and the inner rocker panel ,
refer to Figure 6F – 24.
6F Cabin Floor – Crew Cab Page 6F–14
Page 6F–14
Figure 6F – 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 Body Construction.
8 Apply Joint Sealer (Item 3) as required.
refer to Section 3F Body Construction – Crew Cab .
9 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3F Body Construction – Crew Cab .
10 Reinstall the remaining bolt-on panels and
components as required, refer to the appropriate
Section of the MY2005 VZ Service Information.
Figure 6F – 25
6F Cabin Floor – Crew Cab Page 6F–15
Page 6F–15
2.4 Front Floor Panel Extension Assembly –
Replace
Remove
1 Remove the adjacent bolt-on panels a nd components
as described in the appropriate Section of the MY2005
VZ 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 panel attaching
areas as required.
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 the rear body lower panel,
refer to 2.3 Rear Body Lower Panel – Replace. Figure 6F – 26
6 Remove other adjacent pane ls as required, refer to the relevant Section in this Supplement.
7 Spot cut the welds attaching the floor panel extension assembly to the front floor panel a ssembly, each side of the
vehicle, refer to Figure 6F – 27.
Figure 6F – 27
8 Spot cut the welds attaching the floor panel extension assembly to the inner rocker panel assembly, each side of
the vehicle, refer to Figure 6F – 28.
9 Grind off the MIG weld (1), attaching the floor panel extension assembly to the inner rocker panel assembly, three
places.
6F Cabin Floor – Crew Cab Page 6F–16
Page 6F–16
Figure 6F – 28
10 Remove the floor panel extension assembly from the vehicle and repair any damage to adjacent panels as
required.
11 Check and rectify the alignme nt of the body as required, refer to Section 3 F Body Construction – Cre w Cab .
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 requir ed,
refer to Section 3F Body Construction – Crew Cab .
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3F Body Construction – Crew Cab .
4 Secure the floor extension in positio n an d make several tack welds around its circumference. Spot or plug weld to
the front floor panel assembly and the inner rocker pa nel assembly, refer to Figure 6F – 29.
6F Cabin Floor – Crew Cab Page 6F–17
Page 6F–17
Figure 6F – 29
5 Spot or plug weld the floor panel extension a ssembly to the inner rocker panel assembly, each side of the vehic le,
refer to Figure 6F – 30.
6 MIG weld (1) the floor panel extension assembly to the inner rocker panel assembly, three plac es.
Figure 6F – 30
7 Replace any other remov ed 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 Body Construction.
9 Apply Joint Sealer (Item 3) as required. Refer to Section 3F Body Construction – Crew Cab .
10 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,
refer to Section 3F Body Construction – Crew Cab .
11 Apply Floor Deadeners Pa nels as required, refer to Section 3F Bod y Construction – Cre w Cab .
12 Apply Spray-On Deade ner (Item 7) as required to the underside of the flo or,
refer to Section 3F Body Construction – Crew Cab .
13 Reinstall the remaining bolt-on panels and components as required, refer to the appropriate Section of the MY2005
VZ Service Information.
6F Cabin Floor – Crew Cab Page 6F–18
Page 6F–18
2.5 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 MY2005
VZ 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 adjoining panels as required, refer to the
relevant Section in this Supplement.
4 Using a scraper and heat gun, remove the body sealer
and deadener from the front floor attaching areas.
5 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 6F – 32. Figure 6F – 31
Figure 6F – 32
6 Grind the MIG weld (1) attaching the front floor panel
extension to the front floor panel assembly.
7 Spot cut the welds attaching the front floor panel
extension to the front floor panel assembly.
8 Spot cut the welds attaching the front floor panel
assembly to the front side rail assemblies, each side of
the vehicle, refer to Figure 6F – 34.
Figure 6F – 33
6F Cabin Floor – Crew Cab Page 6F–19
Page 6F–19
Figure 6F – 34
9 Spot cut the welds attaching the front floor panel assembly to the front floor panel extension assembly, each side of
the vehicle, refer to Figure 6F – 35.
Figure 6F – 35
10 Remove the front floor assembly from the vehicle and repair any damage to adjacent panels as required.
11 Check and rectify the alignme nt of the body as required, refer to Section 3 F Body Construction – Cre w Cab .
6F Cabin Floor – Crew Cab Page 6F–20
Page 6F–20
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 3F Body Construction – Crew Cab .
3 Apply Acrylic Spot Weld Sealer (Item 2), refer to Section 3F Body Construction – Crew Cab .
4 Secure the front floor panel assembly in position and make several tack welds around its circumference. Spot or
plug weld the front floor panel assembly to the front floor panel extension and the inner rocker panel assembly.
Figure 6F – 36
5 On each side of the vehicle, spot or plug weld the front floor panel assembly to the front side rail assemblies,
refer to Figure 6F – 37.
6F Cabin Floor – Crew Cab Page 6F–21
Page 6F–21
Figure 6F – 37
6 Spot or plug weld the front floor panel extension to the
front floor panel assembly.
7 MIG weld (1) the front floor panel extension to the front
floor panel assembly.
8 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 6F – 39.
Figure 6F – 38
Figure 6F – 39
9 Replace any other remov ed panels as required, refer to the relevant Section in this Supplement.
10 Refinish and paint panels and other components as required. Refer to Section 3 Body Construction.
11 Apply Joint Sealer (Item 3) as required, refer to Section 3F Body Construction – Crew Cab .
12 Apply Cavity Wax (Item 8) as required to the inside of any box secti ons or areas inaccessible to paint,
refer to Section 3F Body Construction – Crew Cab .
13 Apply floor deadeners as req uired, refer to Section 3F Body Construction – Crew Cab .
14 Apply Spray-On Deade ner (Item 7) as required to the underside of the flo or,
refer to Section 3F Body Construction – Crew Cab.
15 Reinstall the remaining bolt-on panels and components as required, refer to the appropriate Section of the MY2005
VZ Service Information.
6F Cabin Floor – Crew Cab Page 6F–22
Page 6F–22
2.6 Transmission Support Bracket, AWD –
Replace
Remove
1 Remove the adjacent bolt-on panels and components as described in the appropriate section of the MY2005 VZ
Service Information.
2 Using a scraper and heat gun, remove the body sealer and deadener from the front floor attaching areas.
3 Spot cut the welds attaching the transmission support
bracket to the vehicle.
4 Remove the transmission support bracket from the
vehicle and repair any damag e to the adjacent area as
required.
Figure 6F – 40
6F Cabin Floor – Crew Cab Page 6F–23
Page 6F–23
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 3F Body Construction – Crew Cab .
3 Position the transmission support bracket to the
dimensions shown, measuring from the front edge of
the crossmember flange.
NOTE
Positioning of the transmission support bracket is
critical to driveline orientati on.
4 Temporarily bolt the transmission crossmember in
position to help locate the mount.
5 Spot or plug weld the transmission supp ort bracket to
the front floor panel assembly.
6 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
7 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3F Body Construction – Crew Cab .
8 Apply floor deadeners as required,
refer to Section 3F Body Construction – Crew Cab .
Figure 6F – 41
9 Apply Spray-On Deadener (Item 7) as required to the underside of the floor,
refer to Section 3F Body Construction – Crew Cab .
10 Reinstall the remaining bolt-on panels and components as required, refer to the appropriate Section of the MY2005
VZ Service Information.