6 Cabin Floor Page 6-1
Page 6-1
Section 6
Cabin Floor
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 WL 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 Cabin Floor Components...................................................................................................................................... 2
2 Service Operations.................................................................................................................................4
2.1 Front Floor Panel Extension – Replace ............................................................................................................... 4
Remove................................................................................................................................................................... 4
Replace................................................................................................................................................................... 5
2.2 Front Floor Panel Extension – Partial Replace.................................................................................................... 7
Remove................................................................................................................................................................... 7
Replace................................................................................................................................................................... 8
2.3 Front Floor Panel Assembly – Replace.............................................................................................................. 10
Remove................................................................................................................................................................. 10
Replace................................................................................................................................................................. 12
2.4 Inner Rocker Panel Assembly – Replace........................................................................................................... 14
Remove................................................................................................................................................................. 14
Replace................................................................................................................................................................. 15
2.5 Transmission Support Bracket – Replace......................................................................................................... 17
Remove................................................................................................................................................................. 17
Replace................................................................................................................................................................. 17
2.6 Seat Inner Bracket Assembly – Replace............................................................................................................ 19
Remove................................................................................................................................................................. 19
Replace................................................................................................................................................................. 19
2.7 Seat Outer Bracket Assembly – Replace........................................................................................................... 21
Remove................................................................................................................................................................. 21
Replace................................................................................................................................................................. 21
2.8 Propeller Shaft Hanger Assembly – Replace..................................................................................................... 23
Remove................................................................................................................................................................. 23
Replace................................................................................................................................................................. 23
6 Cabin Floor Page 6-2
Page 6-2
1 General Description
This Section describes the replacement procedures for the cabin floor components of the bod y structure.
For the servicing of the rear floor components refer to Section 10 Rear Body.
Removal of bolt-on panels and mecha nica l components is not covered. For information on the removal of these parts,
reference must be made to the appropriate Section in the MY2005 WL 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 3 Body
Construction for details of the correct
materials and their commercially available
equivalents.
1.1 Cabin Floor Components
The shaded components in Figure 6 – 1 are the cabin floor
components dealt with in this Section.
The components and assemblies shown in Figure 6 – 2 and
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 3 Body Construction.
NOTE
Always refer to an Authorised Retailer for spare
parts availability configurations.
Figure 6 – 1
6 Cabin Floor Page 6-3
Page 6-3
Figure 6 – 2
Legend
1 Front Floor Panel Extension
2 Transmission Support Bracket, Right-hand / Left-hand
3 Front Floor Assembly
4 Seat Outer Bracket Assembly, Right-hand / Left-hand
5 Seat Inner Bracket Assembly
6 Propeller Shaft Hanger Assembly
7 Inner Rocker Panel Assembly, Right-hand / Left-hand
6 Cabin Floor Page 6-4
Page 6-4
2 Service Operations
2.1 Front Floor Panel Extension – Replace
Remove
1 Remove the adjacent bolt-on panels and components
as described in the appropriate Section of the MY2005
WL Service Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the appropriate structural s ections
of the vehicle on safety stands.
3 Remove the dash panel asse mbly, refer to
Section 5 Cockpit Module.
4 Remove the adjoining panels as required, refer to the
relevant Section in this Supplement.
5 Using a scraper and heat gun, remove the body sealer
and deadener from the front floor and floor extension
attaching areas. Figure 6 – 3
6 Spot cut the welds on each side of the vehicle,
attaching the front floor panel extension to the front
side rail assembly, front wheelhouse panel assembly
and front floor panel assembly.
Figure 6 – 4
6 Cabin Floor Page 6-5
Page 6-5
7 Spot cut the welds on each side of the vehicle,
attaching the front floor panel extension (1) to the
hinge pillar inner panel (2) fro m the direction shown A.
Figure 6 – 5
8 Spot cut the welds attaching the front floor panel
extension (1) to the front floor pane l assembly (2).
9 Remove the MIG weld (3) from near the footrest
bracket.
10 Remove the front floor panel extension from the
vehicle, then repair any damage to adjace nt parts as
required.
11 Check and rectify the alignment of the body as
required, refer to Section 3 Body Construction.
Figure 6 – 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.
6 Cabin Floor Page 6-6
Page 6-6
NOTE
The new front floor panel extension (1) may be
plug welded in position from above, utilising the
holes cut in the front floor panel assembly (2)
during removal.
2 Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
Section 3 Body Construction.
3 Clamp the new panel in position in the vehicle.
4 Plug weld the front floor panel exte nsion to the front
floor panel assembly.
5 Make a MIG weld (3) near the footrest bracket. Figure 6 – 7
6 On each side of the vehicle, spot or plug weld the front
floor panel extension to the front side rails, front
wheelhouse panel ass embly and front floor panel.
Figure 6 – 8
7 Spot or plug weld the front floor panel extension (1) to
the hinge pillar inner panel (2).
8 Replace any other remov ed 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 3 Body Construction.
11 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint, refer
Section 3 Body Construction.
12 Apply floor deadeners as req uired, refer to
Section 3 Body Construction).
13 Replace the dash panel ass embly, refer to
Section 5 Cockpit Module.
14 Reinstall the remaining b olt-on panels and
components as required, refer to the appropriate
Section of the MY2005 WL Service Information. Figure 6 – 9
6 Cabin Floor Page 6-7
Page 6-7
2.2 Front Floor Panel Extension – Partial
Replace
Remove
1 Remove the adjacent bolt-on panels and components
as described in the appropriate Section of the MY2005
WL Service Information.
2 Secure the vehicle on a suitable fixture. As a
minimum, support the appropriate structural s ections
of the vehicle on safety stands.
3 Remove the dash panel asse mbly,
refer to Section 5 Cockpit Module.
4 Remove the adjoining panels as required, refer to the
relevant Section in this Supplement.
5 Using a scraper and heat gun, remove the body sealer
and deadener from the front floor and floor extension
attaching areas. Figure 6 – 10
6 Mark the front floor panel extension for cutting as
shown. Cut the panel 30 mm inboard from the front
side rail flange.
7 Spot cut the welds attaching the partial front floor
panel extension to the front side rail assembly, front
wheelhouse panel ass embly and front floor panel
assembly.
Figure 6 – 11
8 Spot cut the welds attaching the front floor panel
extension (1) to the hinge pillar inner panel (2) from
the direction shown A.
9 Remove the partial front floor panel e xtension and
repair any damage to adjacent panels as required.
10 Check and rectify the alignment of the body as
required, refer to Section 3 Body Construction.
Figure 6 – 12
6 Cabin Floor Page 6-8
Page 6-8
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.
1 Accurately cut the required section from a new panel, allowing approximately 15 mm overlap for the lap joint.
2 On the new section, trim the glue track back 15 mm to
allow butting against the section on th e vehicle.
3 Flange the new section of front floor panel extensio n
(1) using a suitable tool to for m a joggle (2) to facilitate
the lap joint. The joggle should be towards the interior
of the vehicle.
4 Ensure that the old and new glue tracks (3) align, to
allow installation of the dash panel assembly. The glue
tracks need not be butt welded.
5 As required, mark the new panel with drilling locations
in preparation for plug welding. Drill holes as required.
6 Prepare all mating surfaces and treat with Weld
Through Primer (Item 1) as required, refer to
Section 3 Body Construction.
7 Spot or plug weld (4) the lap joint at a minimum
spacing of 35 mm along the join, then MIG weld along
the engine compartment side of the panels. Figure 6 – 13
8 Spot or plug weld the partial floor panel extension to
the front side rails, front wheelhouse pane l assembly
and front floor panel.
Figure 6 – 14
6 Cabin Floor Page 6-9
Page 6-9
9 Spot or plug weld the front floor panel extension (1) to
the hinge pillar inner panel (2).
10 Replace any other remov ed 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 3 Body Construction.
13 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas i na ccessible to paint,
refer to Section 3 Body Construction.
14 Apply floor deadeners as req uired, refer to
Section 3 Body Construction.
15 Replace the dash panel ass embly, refer to
Section 5 Cockpit Module.
16 Reinstall the remaining b olt-on panels and
components as required, refer to the appropriate
Section of the MY2005 WL Service Information. Figure 6 – 15
6 Cabin Floor Page 6-10
Page 6-10
2.3 Front Floor Panel Assembly – Replace
Care must be taken to avoid cutting the fuel,
brake or emission control pipes.
Remove
1 Remove the adjacent bolt-on panels and components
as described in the appropriate Section of the MY2005
WL Service Information.
2 Remove the adjoining panels as required, refer to the
relevant Section in this Supplement.
3 Secure the vehicle on a suitable fixture. As a
minimum, support the structural sections of the vehicle
on safety stands.
4 Using a scraper and heat gun, remove the body sealer
and deadener from the front floor attaching areas.
5 Spot cut the welds attaching the front floor panel
extension to the front floor panel assembly, refer to
2.1 Front Floor Panel Extension – Replace. Figure 6 – 16
6 From underneath the vehicle, spot cut the welds attaching the front floor panel assembl y to the inner rocker panel
assembly, refer to Figure 6 – 17.
Figure 6 – 17
6 Cabin Floor Page 6-11
Page 6-11
7 From underneath the vehicle, spot cut the welds
attaching the park brake cable bracket to the rear floor
panel assembly.
8 On each side of the vehicle, spot cut the welds
attaching the front floor panel assembly to the front
side rail assemblies, refer to Figure 6 – 19.
Figure 6 – 18
Figure 6 – 19
9 Spot cut the welds attaching the front floor panel
assembly (1) to the rear floor panel assembly (2).
10 Remove the front floor assembly from the vehicle and
repair any damage to adjacen t panels as required.
11 Check and rectify the alignment of the body as
required, refer to Section 3 Body Construction.
Figure 6 – 20
6 Cabin Floor Page 6-12
Page 6-12
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 3 Body Construction.
3 Secure the front floor panel assembly (1) in position
and make several tack welds around its
circumference. Plug weld to the rear floor panel
assembly (2).
4 From underneath the vehicle, spot or plug weld the
front floor assembly to the inner rocker panel
assembly, 14 places forward of the crossmember and
24 places rear of the crossmember. From inside the
vehicle, also spot weld, five places, refer to
Figure 6 – 22.
Figure 6 – 21
Figure 6 – 22
5 Replace the front floor panel extension, or weld the extension to the front floor panel assembly,
refer to 2.1 Front Floor Panel Extension – Replace.
6 On each side of the vehicle, plug weld the front floor panel assembly to the front side rail assemblies,
refer to Figure 6 – 23.
6 Cabin Floor Page 6-13
Page 6-13
Figure 6 – 23
7 Reinstall the park brake cable bracket to the rear floor
panel assembly.
8 Replace any other remov ed 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 3 Body Construction.
11 Apply Cavity Wax (Item 8) as required to the inside of
any box sections or areas inaccessible to paint, refer
to Section 3 Body Construction.
12 Apply floor deadeners as required,
refer to Section 3 Body Construction.
13 Apply Spray-on dea dener (Item 7) as required to the
underside of the floor, refer to
Section 3 Body Construction.
14 Apply fusible reinforcement patches, refer to
Section 3 Body Construction. Figure 6 – 24
15 Reinstall the remaining b olt-on panels and components as required, refer to the appropri ate Section of the MY2005
WL Service Information.
6 Cabin Floor Page 6-14
Page 6-14
2.4 Inner Rocker Panel Assembly – Replace
Remove
1 Remove the adjacent bolt-on panels and components
as described in the appropriate Section of the MY2005
WL 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 adjacent panels as required, refer to the
relevant Section in this Supplement.
4 Spot cut the welds attaching the front floor panel
assembly to the inner rocker panel as required.
Refer to Figure 6 – 26.
Figure 6 – 25
Figure 6 – 26
5 Spot or plug weld the front floor panel assembly to the inner rocker panel, undern eath and inside.
Refer to Figure 6 – 27
Figure 6 – 27
6 Cabin Floor Page 6-15
Page 6-15
6 Remove the two MIG welds (1) attaching the inner
rocker panel to the hinge pillar inner assembly.
7 If not already done so, remove the four spot welds
attaching the inner rocker panel to the hinge pillar
inner assembly and rocker panel re inforcement.
8 Remove the inner rocker panel from the vehicle a nd
repair any damage to adjacen t panels as required.
9 Check and rectify the alignment of the body as
required, refer to Section 3 Body Construction.
Figure 6 – 28
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 3 Body Construction.
3 Clamp the inner rocker panel in positi on, noting to ensure it fits behind the hinge pillar inner assembly.
4 Make two MIG welds (1), to attach inner rocker panel
to the hinge pillar inner assem bl y.
NOTE
The four plug welds are to be made once the
door opening frame assembly is installed.
5 Plug weld the inner rocker panel to the rear floor panel
outer extension (A), centre crossmember (B) and front
floor panel support (C), refer Figure 6 – 30.
Figure 6 – 29
6 Cabin Floor Page 6-16
Page 6-16
Figure 6 – 30
6 Spot or plug weld the front floor panel assembly to the inner rocker panel, undern eath and inside,
refer to Figure 6 – 31.
Figure 6 – 31
7 Replace the adjoining removed panels as required, refer to the relevant Se ction 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 3 Body Construction.
10 Apply Cavity Wax (Item 8) as required to the inside of any box sections or areas inaccessible to paint,
refer to Section 3 Body Construction.
11 Reinstall the remaining b olt-on panels and components as required, refer to the appropri ate Section of the MY2005
WL Service Information.
6 Cabin Floor Page 6-17
Page 6-17
2.5 Transmission Support Bracket – Replace
Remove
1 Remove the adjacent bolt-on panels and components as described in the appropriate Section of the MY2005 WL
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 18 welds for the right-hand side or 23 welds for the left-hand side attaching the transmission support
bracket to the front floor panel assembly as required, refer to Figure 6 – 32.
4 Remove the transmission support bracket from the vehicle and repair an y damage to the adjacent area as
required.
Figure 6 – 32
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 3 Body Construction.
NOTE
Positioning of the transmission support brac ket is
critical to driveline orientation. Incorrect location
can cause driveline vibrations.
3 Position the transmission support bracket so that the rear tooling hole centre is 190 mm from the vehicle centre and
225 mm rearward of the datum hole centres in the floor, refer to Figure 6 – 24.
6 Cabin Floor Page 6-18
Page 6-18
4 Temporarily bolt the transmission crossmember in position to help locate the mount. Check the crossmember for
correct orientation to the vehicle.
5 Clamp or tack weld the mount in position and recheck positioning.
6 Spot or plug weld the mount assembly to the floor, 18 places for the right-hand side or 22 places for the left-hand
side, refer to Figure 6 – 24.
Figure 6 – 33
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 3 Body Construction.
9 Apply Cavity Wax (Item 8) as required to the inside of any box sections or areas inaccessible to paint,
refer to Section 3 Body Construction.
10 Apply floor deadeners as req uired, refer to Section 3 Body Construction.
11 Apply Spray-on dea dener (Item 7) as required to the underside of the floor, refer to Section 3 Bod y Construction.
12 Reinstall the remaining b olt-on panels and components as required, refer to the appropri ate Section of the MY2005
WL Service Information.
6 Cabin Floor Page 6-19
Page 6-19
2.6 Seat Inner Bracket Assembly – Replace
Remove
1 Remove the adjacent bolt-on panels and components as described in the appropriate Section of the MY2005 WL
Service Information.
2 As required, use a scraper and heat g un to remove the body sealer and deadener from the front floor and floor
extension attachin g areas.
3 Lower the transmission rear mount and pro peller shaft centre bearing assembl y to avoid damage from heat, refer to
the appropriate section of the MY2005 WL Service Information.
4 Spot cut the 39 welds each side attaching the seat
inner bracket assembly to the floor.
5 Spot cut the four welds each side attaching the
bracket assembly to the floor and propeller shaft
hanger assembly.
6 Spot cut the two welds front and rear attaching the top
of the bracket assembly to the floor.
7 Spot cut the weld attaching the right-hand side of the
bracket assembly to the floor.
8 Remove the bracket assembly from the vehicle and
repair any damage to the adjacent area as required.
Figure 6 – 34
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 3 Body Construction.
6 Cabin Floor Page 6-20
Page 6-20
3 Install the seat inner bracket assembly in position and
check that the seat mount holes will align with the
seat.
4 Spot or plug weld the bracket assembl y to the floor
(and propeller shaft hanger assembly if required) as
shown.
5 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
6 Apply floor deadeners as req uired, refer to
Section 3 Body Construction.
7 Reinstall the transmission re ar mount, refer to
Section 7B Manual Transmission or
Section 7C Automatic Transmission in the MY2005
WL Service Information.
8 Reinstall the propeller sh aft centre bearing assembly,
refer to Section 4C1 Rear Propeller Shaft and
Universal Joint in the MY2005 WL Service Information.
9 Reinstall the remaining b olt-on panels and
components as required, refer to the appropriate
Section of the MY2005 WL Service Information.
Figure 6 – 35
6 Cabin Floor Page 6-21
Page 6-21
2.7 Seat Outer Bracket Assembly – Replace
Remove
1 Remove the adjacent bolt-on panels and components as described in the appropriate Section of the MY2005 WL
Service Information.
2 Using a scraper and heat gun, remove the body sealer and deadener from the front floor attaching areas.
3 From the underside of the floor, remove deadener in the area of the reinforcement.
4 Spot cut the 21 welds attaching the seat outer bracket
assembly to the floor.
5 Remove the bracket assembly from the vehicle and
repair any damage to the adjacent area as required.
Figure 6 – 36
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 3 Body Construction.
6 Cabin Floor Page 6-22
Page 6-22
3 Install the seat outer bracket assembly in position and
check that the seat mount holes will align with the
seat.
4 Spot or plug weld the bracket assembly to the floor, 21
places as shown.
5 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
6 Apply Spray-on dea dener (Item 7) as required to the
underside of the floor, refer to
Section 3 Body Construction.
7 Apply floor deadeners as req uired, refer to
Section 3 Body Construction.
8 Reinstall the remaining b olt-on panels and
components as required, refer to the appropriate
Section of the MY2005 WL Service Information.
Figure 6 – 37
6 Cabin Floor Page 6-23
Page 6-23
2.8 Propeller Shaft Hanger Assembly –
Replace
Remove
1 Remove the adjacent bolt-on panels and components as described in the appropriate Section of the MY2005 WL
Service Information.
2 Remove the propeller shaft and centre bearing assembly,
refer to Section 4C1 Rear Propeller Shaft and Universal Joint in the MY2005 WL Service Information.
3 Using a scraper and heat gun, remove the body sealer and deadener from the front floor attaching areas.
4 Spot cut the two welds front and three welds rear
attaching the propeller shaft hanger assembly to the
floor.
5 Spot cut the seven welds each side attaching the
hanger assembly to the floor.
6 Spot cut the four welds each side attaching the hang er
assembly to the floor and seat inner bracket assembl y.
7 Remove the hanger assembly from the vehicle and
repair any damage to the adjacent area as required.
Figure 6 – 38
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 3 Body Construction.
6 Cabin Floor Page 6-24
Page 6-24
3 Install the propeller shaft hanger assembly, positioning
each front datum hole 162 mm forward of the datum
hole centres in the floor.
4 Spot or plug weld the hanger assembl y to the floor,
two places front and three places rear.
5 Spot or plug weld the hanger assembl y to the floor,
seven places each side.
6 Spot or plug weld the hanger assembly to the floor and
seat inner bracket assembly, four places each side.
7 Refinish and paint panels and other components as
required. Refer to Section 3 Body Construction .
8 Apply Spray-on dea dener (Item 7) as required to the
underside of the floor, refer to
Section 3 Body Construction.
9 Apply floor deadeners as req uired, refer to
Section 3 Body Construction.
Figure 6 – 39
10 Install the propeller shaft and centre bearing assembly,
refer to Section 4C1 Rear Propeller Shaft and Universal Joints in the MY2005 WL Service Information.
11 Reinstall the remaining b olt-on panels and components as required, refer to the appropri ate Section of the MY2005
WL Service Information.