Cargo Box Side Panel Replacement - Inner

Cargo Box Side Panel Replacement - Inner

Removal Procedure





1. The replacement cargo box side panel is serviced as a complete assembly, including the cargo cover mounting bracket. If damage is less severe the cargo box side panel may be removed without removing the outer quarter panel or the outer wheelhouse.

Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer to Rear Compartment in Dimensions - Body (Motor Compartment) ()Dimensions - Body (Windshield Opening) ()Dimensions - Body (Door Opening) ()Dimensions - Body (Rear Panel Opening) ()Dimensions - Body (Roof Stowage Compartment) ()Dimensions - Body (Rear Compartment) () .

Caution: Refer to Foam Sound Deadeners Caution in Cautions and Notices.

5. 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.





Important: Do not damage any inner panels or reinforcements.


6. Locate and drill out all factory welds. Note the number and location of welds for installation of the service side panel.




7. Verify the existence of structural weld-through adhesive. Refer to Structure Adhesive - Identification () . If necessary use a chisel to separate the side panel from the adjacent panels.




8. Remove the damaged side panel.



Installation Procedure





1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in locations noted from the original panel.
2. Replace the structural adhesive with an additional plug weld between the existing plug welds, where necessary.
3. Prepare all mating surfaces as necessary.
4. Apply 3M(R) Weld-Thru coating P/N 05916 or equivalent to all mating surfaces




5. Position the service side panel. Align and inspect for proper positioning. Refer to Rear Compartment in Dimensions - Body (Motor Compartment) ()Dimensions - Body (Windshield Opening) ()Dimensions - Body (Door Opening) ()Dimensions - Body (Rear Panel Opening) ()Dimensions - Body (Roof Stowage Compartment) ()Dimensions - Body (Rear Compartment) () .




6. Plug weld accordingly.
7. Clean and prepare all welded surfaces.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair () in Paint and Coatings.
9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems (Basecoat/Clearcoat Paint Systems) in Paint and Coatings.
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
12. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.