9C Roof – Utility and Regular Cab Page 9C-1
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Section 9C
Roof – Utility and Regular 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 Description ...............................................................................................................................2
1.1 Roof Components.................................................................................................................................................. 2
Utility and Regular Cab ......................................................................................................................................... 3
2 Service Operations.................................................................................................................................4
2.1 Roof Panel – Replace ............................................................................................................................................ 4
Remove................................................................................................................................................................... 4
Replace................................................................................................................................................................... 6
2.2 Roof Front Header Panel – Replace ..................................................................................................................... 8
2.3 Roof Rear Panel – Replace ................................................................................................................................... 9
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1 General Description
This Section describes the replacement procedures for the roof structure. The components covered include the roof
panel and the roof header a nd rear panels.
Removal of trim and bolt-on components is not covered. Reference must be made to the appropriate Sections of the MY
2005 VZ 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.
When repairing the roof structure, care must be taken to ensure it is returned to its original prod uction configuration.
NOTE
It is imperative that the correct body adhesives,
sealers, deadeners and cavity waxes are used
when repairing the body structure. Refer to
Section 3C Body Construction – Utility or
Section 3E Body Construction – Regular Cab for
details of the correct materials and their
commercially available equivalents.
1.1 Roof Components
The shaded components in Figure 9C – 1 are those dealt
with in this Section.
The components and assemblies shown in Figure 9C – 2
are the serviceable parts that form the basis of the repair
procedures in this Section. For a detailed view of the body
components, refer to Section 3C Body Construction – Uti lity
or Section 3E Body Construction – Re gular Cab.
NOTE
Always refer to an Authorised Retailer for spare
parts availability configurations.
Figure 9C – 1
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Utility and Regular Cab
Figure 9C – 2
Legend
1 Roof Panel
2 Roof Front Header Panel 3 Roof Rear Panel
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2 Service Operations
2.1 Roof Panel – Replace
Remove
1 Remove the adjacent trim and components as described in the appropriate Section of the MY 2005 VZ Service
Information.
2 Remove the windshield an d rear window, refer to Section 1A6 Stationary Windows in the MY 2005 VZ Service
Information.
3 Spot cut the welds attaching the roof panel to the roof
front header panel.
Figure 9C – 3
4 Spot cut the welds attaching the roof panel to the roof
rear panel.
5 Spot cut the three welds each side attaching the roof
panel to the door opening frame and side inner upper
front panel.
Figure 9C – 4
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6 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 securely glued to the
body side panel along the channel it cannot
be removed by simply spot cutting the welds.
• If the roof front header and roof rear panel
are to be retained, take care not to cut them
off with the roof panel. Alternatively, if one or
all are to be re placed, it is easier to c ut those
being replaced off with the roof panel.
Figure 9C – 5
7 Use a heat gun to soften the Anti-flutter adhesive
between the roof front header panel, roof bow panels
and roof rear panel by heating the areas shown.
Figure 9C – 6
8 Cut through the softened adhesive between the roof
panel and roof front header panel, roof bow panels
and roof rear panel using a suitable tool.
9 Remove the roof panel from the vehicle.
Figure 9C – 7
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10 Using an angle grinder, air chisel or other suitable tool,
remove the remaining strip of roof panel from the body
side panel, along with the adhesive ben eath the strip.
11 Repair any damage to adjacent parts.
12 Check and rectify the alignme nt of
the body as required, refer to
Section 3C Body Construction – Utility.
Figure 9C – 8
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.
• When welding a relatively flat panel such as
the roof panel, due care must be taken to
minimise the heat absorbed by the panel
which could lead to panel d istortion.
1 Clean any remaining Anti-fl utter adh esive from the surface of the roof front header panel, roof bow panels and roof
rear panel.
2 Prepare the mating areas for welding. Dress the channel flange area, the roof front header and roof rear panel.
These areas should be flat and free from imperfections.
3 As required, mark the new panel with drilling locations in preparation for plug welding. Drill holes as req uired.
4 Apply Structural Adhesive (1) (Item 6), refer to
Section 3C Body Construction – Utility.
Figure 9C – 9
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5 Apply a bead of Anti-flutter Adhesiv e (Item 5)
to the full length of the groove in the roof
front header panel and roof rear panel.
Refer to Section 3C Body Construction – Utility.
6 Apply two full length bea ds of Anti-flutter adhesive to
the grooves in the roof bow pane ls.
Figure 9C – 10
7 Spot or plug weld the roof panel to the door opening
frame on both sides of the vehicle.
NOTE
• Take care to minimise the heat absorbed by
the panel in order to reduce h eat distortion.
• 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.
8 Spot or plug weld the roof panel to the roof front
header panel, roof rear panel and the door opening
frame and side inner upper front panel each side, refer
to Figure 9C – 12. Figure 9C – 11
Figure 9C – 12
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 3C Body Construction – Utility.
11 Apply Cavity Wax (Item 8) as required to the inside of any box sections or ar eas inaccessible to paint, refer to
Section 3C Body Construction – Utility.
12 Replace the windshield, refer to Section 1A6 Stationary Windows in the MY 2005 VZ Service Information.
13 Install the remaining components as described in the appr opriate Section of the MY 2005 VZ Service Information.
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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 tre at with Weld Through Primer (Item 1) as required, refer to,
Section 3C Body Construction – Utility or Section 3E Bod y Construction – Regular Cab.
The two spot welds (1) are removed with the roof panel.
Remove the five spot welds (2) from each side of the vehicle
to remove the roof front header panel.
Figure 9C – 13
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2.3 Roof Rear Panel – Replace
Following removal of the roof panel, as required spot cut the welds attaching the roof rea r panel as shown in the
following diagram.
When installing a roof rear panel, eith er 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 tre at with Weld Through Primer (Item 1) as required, refer to
Section 3C Body Construction – Utility or Section 3E Bod y Construction – Regular Cab.
Remove the six spot welds from each si de of the vehicle to
remove the roof rear panel.
Figure 9C – 14