9F Roof – Crew Cab Page 9F–1
Page 9F–1
Section 9F
Roof – 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 Roof Components.................................................................................................................................................. 2
Crew Cab ................................................................................................................................................................ 2
2 Service Operations – Crew Cab............................................................................................................3
2.1 Roof Panel – Replace ............................................................................................................................................ 3
Remove................................................................................................................................................................... 3
Replace................................................................................................................................................................... 6
2.2 Roof Front Header Panel – Replace ..................................................................................................................... 8
2.3 Roof Bow Panel – Replace.................................................................................................................................... 9
2.4 Roof Rear Outer Panel – Replace....................................................................................................................... 10
Remove................................................................................................................................................................. 10
Replace................................................................................................................................................................. 11
2.5 Roof Rear Inner Panel – Replace........................................................................................................................ 12
Remove................................................................................................................................................................. 12
9F Roof – Crew Cab Page 9F–2
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1 General Information
This Section describes the replacement procedures for the roof structure. The components covered include the roof
panel and the roof header, bo w and re ar panels.
Removal of trim and bolt-on components is not covered. Reference must be made to the appropriate Sections of the
MY2005 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 3F Body
Construction – Crew Cab for details of the
correct materials and their commercially
available equivalents.
1.1 Roof Components
The shaded components in Figure 9F – 1 are those dealt
with in this Section.
The components and assemblies shown in Figure 9F – 2
are the parts serviced for 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 3F Body Construction – Crew Cab.
NOTE
Always refer to an Authorised Dealer for spare
parts availability configurations.
Figure 9F – 1
Crew Cab
Figure 9F – 2
Legend
1 Roof Front Header Panel
2 Roof Panel
3 Roof Bow Panel
4 Roof Rear Inner Panel
5 Roof Rear Outer Panel
9F Roof – Crew Cab Page 9F–3
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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 MY2005 VZ Service
Information.
2 Remove the adjacent bolt-on panels and components as described in the appropriate Section of the MY2005 VZ
Service Information.
3 Remove the windshield an d rear window, refer to Section 1A6 Stationary Windows in the MY2005 VZ 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 along the rear of
the roof, refer to Figure 9F – 4.
NOTE
As the roof panel is attached with structural
adhesive (1) to the roof rear outer panel, it
cannot be removed by simply spot cutting the
welds.
Figure 9F – 3
Figure 9F – 4
9F Roof – Crew Cab Page 9F–4
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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 i nner a nd outer pa nels ar e to be
retained, take care not to cut them off with the
roof panel. Alternatively, if one or more are to be
replaced, it is easier to cut off those being
replaced along with the roof panel.
Figure 9F – 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 9F – 6
9 Cut through the softened adhesive between the roof
panel and roof front header pa nel, roof bow panel and
roof rear panel using a suitable tool.
10 Remove the roof panel from the vehicle.
Figure 9F – 7
9F Roof – Crew Cab Page 9F–5
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11 Using an angle grinder, air chisel 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 9F – 8
12 Using an angle grinder, air chisel 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 body as required, refer to
Section 3F Body Construction – Crew Cab.
Figure 9F – 9
9F Roof – Crew Cab Page 9F–6
Page 9F–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.
• 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 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 front header 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 plug welding. Drill holes as req uired.
4 Apply Structural Adhesive (Item 6), refer to Section 3F Bod y Constructio n – Crew Cab, to the door opening frame
assembly flange (1) and rear roof header outer panel fla nge (2), refer to Figure 9F – 10.
Figure 9F – 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 3F Body Construction – Crew Cab.
6 Apply two full length bea ds of Anti-flutter adhesive to
the grooves in the roof bow pane l, refer to
Section 3F Body Construction – Crew Cab.
7 Position the roof panel on the vehicle and clamp in
place.
Figure 9F – 11
9F Roof – Crew Cab Page 9F–7
Page 9F–7
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 9F – 12
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 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 sections or areas i na ccessible to paint,
refer to Section 3F Body Construction – Crew Cab.
13 Replace the windshiel d and rear window, refer to
Section 1A6 Stationary Windows i n the MY2005 VZ
Service Information.
14 Install the remaining components as described in the
appropriate Section of the MY2005 VZ Service
Information.
Figure 9F – 13
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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 3F Body Construction – Crew Cab.
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 body as required, refer to
Section 3F Body Construction – Crew Cab.
Figure 9F – 14
9F Roof – Crew Cab Page 9F–9
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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 diagram.
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 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 3F Body Construction – Crew Cab.
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 adjacen t parts as required.
4 Check and rectify the alignme nt of
the body as required, refer to
Section 3F Body Construction – Crew Cab.
Figure 9F – 15
9F Roof – Crew Cab Page 9F–10
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2.4 Roof Rear Outer Panel – Replace
Remove
1 Remove the adjacent bolt-on panels and components as described in the appropriate Section of the MY2005 VZ
Service 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 outer panel in from the forward
flange and in from each end (1), refer to Figure 9F – 16.
Figure 9F – 16
4 Spot cut the welds, three places, attaching the roof rear outer panel to the roof rear inner panel and quarter panel
inner assembly. Repeat for the opposite side of the vehicle.
5 Spot cut the welds attaching the roof rear outer panel to the roof rear inner panel.
6 Remove the roof rear outer panel from the vehicle.
7 Using a cutting tool such as an air chisel or a ngle grinder, remove the remaining strip of roof rear outer panel, along
with the adhesive beneath the strip.
8 Repair any damage to adjacent parts as required.
9 Check and rectify the alignment of the body as required, refer to Section 3F Body Construction – Crew Cab.
9F Roof – Crew Cab Page 9F–11
Page 9F–11
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 b e 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 Prepare the mating surfaces and treat with Weld Through Primer (Item 1) as required,
refer to Section 3F Body Construction – Crew Cab.
2 Apply Structural Adhesive (1, Item 6), refer to Section 3F Body Construction – Crew Cab, refer to Figure 9F – 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 outer panel to the quarter panel inner
assembly and roof rear inner pane l.
Figure 9F – 17
5 Refinish and paint panels and other components as required. Refer to Section 3 Body Construction.
6 Apply Joint Sealer (Item 3) as required, refer to Section 3F Body Construction – Crew Cab.
7 Apply Cavity Wax (Item 8) as required to the inside of any box sections or ar eas inaccessible to paint, refer to
Section 3F Body Construction – Crew Cab.
8 Reinstall the remaining components as described in the appropriate Section in the MY2005 VZ Service Information.
9F Roof – Crew Cab Page 9F–12
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2.5 Roof Rear Inner Panel – Replace
Remove
Following removal of the roof panel, as required spot cut the welds attaching the roof rear inner panel as shown in the
following diagram.
When installing a roof rear inner panel, either spot weld the part to the vehicle or mark and drill the ne w 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 3F Body Construction – Crew Cab.
1 Spot cut the welds from each side of the vehicle
attaching the roof rear inner pane l.
2 Remove the roof rear inner panel from the vehicle and
repair any damage to adjacen t parts as required.
3 Check and rectify the alignme nt of
the body as required, refer to
Section 3F Body Construction – Crew Cab.
Figure 9F – 18