Mitsubishi Galant (2004+). Manual - part 34

BODY REPAIR

TSB Revision

BASE OF BODY REPAIR

9-15

NOTE: If a replacement panel is to be mounted by doing 
plug welding from the side of the panel remaining on the 
body, either a hole can be made in the panel on the body, or 
a hole can be made right through both the panel which is to 
remain on the body and the panel to be replaced.

CAUTION

When performing this operation, warping of the surround-
ing panels may occur if an excessive amount of heat is 
applied; therefore, be careful to avoid doing this.
4. Breaking of brazing and arc welds

Heat only the brazed or arc welded portion (such as the 
upper portion of pillars, etc.), and then separate by using a 
screwdriver while melting occurs.

5. Finishing work of spot welding

Grind and smooth any weld traces which might be left on the 
body surface by using an air grinder or similar tool, being 
careful not to damage any of the panels which is not to be 
replaced. When performing this operation, be sure to wear 
safety goggles (dustproof glasses).

6. Making of holes in new parts for MIG plug welding

Make holes approximately 5 

−

 6 mm (0.2 inch) in diameter at 

points where plug welding is to be performed because spot 
welding is not possible.

AB200054

AB200055

AB200056

AB200057

BODY REPAIR

TSB Revision

BASE OF BODY REPAIR

9-16

7. Flange correction for spot weld traces

Correct any flanges that become bent or deformed when 
spot welds are broken or during other work.

CAUTION

Do not use a flame for paint coat removal because doing 
so might damage the paint coat of panels which are not to 
be replaced, thus causing corrosion.
8. Removal of the paint coat from new parts and from the 

vehicle body
In order to provide for the proper flow of electric current 
during spot welding operations, remove the paint coat from 
both sides of the new part and the body by using a polisher 
wheel or similar tool.

9. Rough cutting of new parts

Cut off the unnecessary portions of new parts. Allow an 
overlap of approximately 30 

−

 50 mm (1.2 

−

 2.0 inches) 

when performing overlap cutting of the pillars, side sills, or 
other locations.

CAUTION

Carefully select the location for cutting, taking care not to 
cut a reinforcement at the inner side of a pillar, etc. or a 
panel that is not to be replaced.
10.Overlap cutting of new parts

For locations in which butt welding is to be done, first 
temporarily attach the new parts to the body, and then cut 
the two panels simultaneously.
NOTE: If a reinforcement or a panel which is not to be 
replaced is cut accidentally, first repair the mistake by weld-
ing before proceeding with the rest of the work.

AB200058

AB200059

AB200060

AB200061

AB

EDGE OF THE 
NEW PART

EDGE OF THE 
PANEL ON THE BODY

BODY REPAIR

TSB Revision

BASE OF BODY REPAIR

9-17

CAUTION

Perform the operations carefully so that the cut ends fit 
together properly.
11.Cutting of new parts by using a measurement marking

If overlap cutting is not possible in a place where butt 
welding is to be done, make a measurement marking on the 
new part at the exact same measurement which was used 
for the cutting of the body panel, and then cut the new part 
by using this measurement marking.

•

Two-layer construction
When cutting a front pillar or center pillar which has a 
two-layer construction but no reinforcement, make the cut-
ting of the inner panel and that of the outer panel approxi-
mately 50 mm (2.0 inches) apart in order to obtain 
maximum strength.

•

Three-layer construction
When cutting a front pillar or center pillar which has a 
three-layer (including a reinforcement) construction (dou-
ble-box construction), cut the outer panel and the reinforce-
ment at the same position, and don't forget to butt weld the 
reinforcement. If the inner panel is an assembly replace-
ment part, cut it at two places in order to provide ample 
working space for the butt welding of the reinforcement.

12.Application of spot sealer to spot-welded points

Apply an electro-conductive spot sealer to the connecting 
surfaces of both the new parts and the vehicle body in order 
to provide corrosion protection.

AB200062AB

OUTER PANEL

APPROX. 50 mm

(2.0 in)

INNER PANEL

TWO-LAYER
CONSTRUCTION

AB200063AB

INNER PANEL

INNER PANEL
CUT LINE

INNER PANEL CUT LINE

OUTER PANEL
AND REINFORCE-
MENT CUT LINE

THREE-LAYER CONSTRUCTION

AB200064

BODY REPAIR

TSB Revision

BASE OF BODY REPAIR

9-18

CAUTION

During temporary mounting, it is extremely important to 
obtain accurate measurements for each component. The 
mounting positions for the front and rear suspensions are 
especially crucial with regard to safety; therefore, it is nec-
essary that all work concerning these areas be done care-
fully and correctly.
13.Temporary mounting of new parts

(1) In order to bring the new parts into the proper mounting 

position, measure each part carefully and make any 
corrections necessary in order to obtain agreement with 
the measurements.

(2) In addition, make temporary welds, and then check to 

confirm that the closing and fit of the doors, fenders, etc., 
are correct.
For parts which should be symmetrical to the body 
center, measure the distances from the body center point 
to both the left part and the right part, and confirm that the 
distances are the same.

CAUTION

Weld completely so that there are no pinholes.
14.Butt welding

For burr welding, make a 10 

−

 15 mm (0.4 

−

 0.6 inch) MIG 

spot weld, and then, in order to prevent warping which might 
be caused by the welding heat, complete the welding by 
making welds of the specified width at alternate positions.

AB200065

AB200066

AB200067

AB200068