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Replacement 1. Remove the related parts. • Front seat • Carpet • Refer to the front side frame (see page ). 2. Pull out and straighten the damaged area. • The front side extension receives impact through the front side frame or side sill. Such impact generally requires replacement of all these parts. • Before cutting off the front side extension or side sill, pull out the damaged area with the frame straight- ener and correct the related parts such as the front floor and dashboard. Check the clearance and level differences of the front doors. • Jack up the body and place safety stands at the four designated places of the side sills. If necessary, place safety stands at the rear of the frame. 3. Peel off the undercoat. Heat the undercoat at the weld areas of the front side outrigger and side frame with a gas torch and peel off the undercoat with a metal spatula. CAUTION: Be careful not to burn the fittings inside the passenger compartment when heating. 4. Remove the front side extension. • Center punch around the spot weld imprints on the front side extension from inside the passenger com- partment. • Drill holes is the spot welded areas with a 5 mm (0.2 in) drill. NOTE: Drill holes through the parts completely since the replacement front side extension will be welded by MIG welding. • Level off and finish the burrs of the pried off spot welds with a disc sander. To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding. 5. Mold the related parts. Reshape the lower dashboard, front side frame, front floor, inside sill and side sill inner joint using a hammer and dolly. • Center punch around the spot weld imprints on the front side frame, floor frame and inside sill. • Drill holes using a spot cutter. NOTE: When drilling holes be careful not to drill down to the front side frame, floor frame and inside sill. Main Menu Table of Contents |