Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Remove all related panels and components.
- Restore as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
- Cut the rocker panel below the door hinge welde in front of the body hinge pillar and on the center pillar and the lock pillar.
- Locate and drill out all factory welds. Note the number and location of the welds for installations of the service part.
- Remove the damaged rocker panel.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. The door frame can be replaced at factory seams, but requires the removal of the upper fender rail, windshield, roof and quarter panel. The sectioning procedures have been developed as a more cost-effective alternative to complete replacement. The specific area to be sectioned is determined by the extent of the damage to the vehicle.
Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Cut the replacement rocker panel section in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow 1½ times the metal thickness at the sectioning joint.
- Create a 100 mm (4 in) backing plates from the unused portion of the service part. Trim the backing plates as necessary to fit behind the sectioning joints where there is no reinforcement.
- Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1½ in) apart.
- Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut.
- Prepare all attachment surfaces as necessary.
- Apply 3m weld-thru coating P/N 05916 or equivalent to all mating surfaces.
- Fit the backing plates halfway into the sectioning joints, clamp and plug weld to the vehicle.
- Position the rocker panel to the vehicle using 3-dimensional measuring equipment. Clamp the rocker panel into place.
- Plug weld accordingly.
- Stitch weld the sectioning joints making a 25 mm (1 in) stitch welds along the seams with 25 mm (1 in) gaps between them.
- Complete the stitch weld with minimum heat distortion.
- Clean and prepare all welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
- Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
- Install all related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.
Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.
Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.