10F Body Rear – Crew Cab Page 10F–1
Page 10F–1
Section 10F
Body Rear – 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 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................................................................................................................................................................... 9
10F Body Rear – Crew Cab Page 10F–2
Page 10F–2
1 General Information
This Section describes replacement procedures for the rear components of the Crew Cab body structure. Removal of
bolt-on and mechanical components is not covered. Reference must be made to the appropriate Sections in the MY
2005 VZ Service Information.
For removal of the rear subframe assembly refer to 1B Sheetmetal in the MY 2005 VZ 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. Refer to Section 3F Body
Construction – Crew Cab for details of the
correct materials and their commercially
available equivalents.
1.1 Body Rear Components
The shaded components in Figure 10F – 1 are those de alt
with in this Section.
The components and assemblies shown in
Figure 10F – 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 10F – 1
Figure 10F – 2
Legend
1 Rear Body Upper Inner Panel Assembly
2 Rear Body Upper Outer Panel Assembly 3 Rear Body Lower Panel Assembly
10F Body Rear – Crew Cab Page 10F–3
Page 10F–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
2005 VZ Service Information.
Figure 10F – 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 10F – 4
10F Body Rear – Crew Cab Page 10F–4
Page 10F–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 body as required, refer to
Section 3F Body Construction – Crew Cab.
Figure 10F – 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 requir ed,
refer to Section 3F Body Construction – Crew Cab.
3 Clamp the rear body lower panel assembly in position on the vehicle.
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 10F – 6
10F Body Rear – Crew Cab Page 10F–5
Page 10F–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 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 requ ired to the inside of
any box sections or areas inaccessible to paint,
refer to Section 3F Body Construction – Crew Cab.
11 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10F – 7
10F Body Rear – Crew Cab Page 10F–6
Page 10F–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
2005 VZ Service Information.
2 Remove the rear end lower panel, refer to
2.1 Rear Body Lower Panel Assembly – Replace.
3 Grind off the MIG welds (1) on each side of the
vehicle, attaching the rear body u pper outer panel
assembly to the quarter panel inner,
refer to Figure 10F – 9.
4 Spot cut the welds on each side of the vehicle,
attaching 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. Figure 10F – 8
NOTE
If the rear body upper inner panel assembly is
also to be removed, spot cut and grind off only
the relevant welds.
Figure 10F – 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 body as required, ref er to Section 3 F Body Construction – Cre w Cab.
10F Body Rear – Crew Cab Page 10F–7
Page 10F–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 requir ed,
refer to Section 3F Body Construction – Crew Cab.
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 pane l
assembly to the rear body upper inner pane l assembly and the side body inner p anel, refer to Figure 10F – 10.
5 MIG weld (1), the rear body upper outer panel assembly to the quarter panel inner on each side of the vehicle.
Figure 10F – 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 3F Body Construction – Crew Cab.
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 ar eas inaccessible to paint, refer to
Section 3F Body Construction – Crew Cab.
10 Install the remaining components as described in the appropriate Section of the MY 2005 VZ Service Informatio n.
10F Body Rear – Crew Cab Page 10F–8
Page 10F–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
2005 VZ 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 10F – 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 body as required, refer to
Section 3F Body Construction – Crew Cab.
Figure 10F – 12
10F Body Rear – Crew Cab Page 10F–9
Page 10F–9
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 Clamp the rear body upper i nner panel in position on the ve hicle.
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 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 sections or areas inaccessible to paint,
refer to Section 3F Body Construction – Crew Cab.
11 Install the remaining components as described in the
appropriate Section of the MY 2005 VZ Servic e
Information.
Figure 10F – 13