1. Fit and secure wiring.
2. Fit tail door aperture seal.
3. Fit head lining rear trim finisher.
4. Fit tail door tread plate.
5. Fit exhaust tailpipe heatshield.
6. Fit rear folding step.

EXTERIOR FITTINGS, REPAIRS,

Rear folding step.

7. Fit rear bumper assembly.

EXTERIOR FITTINGS, REPAIRS,

Bumper assembly - rear - up to 03MY.

8. Fit loadspace carpet.

INTERIOR TRIM COMPONENTS,

REPAIRS, Carpet - loadspace.

9. Connect leads/multiplug to alternator.

10. Connect battery leads, negative lead last.

PANEL REPAIRS

77-2-48 REPAIRS

Cross member outer rear panel (RH/LH
section)

In this procedure, the panel body side assembly and
the 'E' post assembly are replaced in conjunction
with either the RH or LH section of the cross member
outer rear panel.

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove 'E' post assembly.

PANEL REPAIRS, REPAIRS, 'E' post

assembly.

4. Remove rear folding step.

EXTERIOR FITTINGS, REPAIRS,

Rear folding step.

5. LH side: Remove exhaust tailpipe heatshield.
6. Remove relevant wiring.

Repair

1. Remove existing panel(s), prepare panel joint

faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

Refit

1. Fit and secure wiring.
2. LH side: Fit exhaust tailpipe heatshield.
3. Fit rear folding step.

EXTERIOR FITTINGS, REPAIRS,

Rear folding step.

4. Fit 'E' post assembly.

PANEL REPAIRS, REPAIRS, 'E' post

assembly.

5. Connect leads/multiplug to alternator.
6. Connect battery leads, negative lead last.

Cross member closing rear panel

In this procedure, the cross member outer rear panel
is replaced in conjunction with the cross member
closing rear panel. The cross member rear assembly
can also be replaced, if required.

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove cross member outer rear panel.

PANEL REPAIRS, REPAIRS, Cross

member outer rear panel.

4. Remove fuel tank.

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Tank - fuel.

FUEL DELIVERY SYSTEM - Td5,

REPAIRS, Tank - fuel.

5. Remove 2 rear bolts securing body rear to

chassis.

Repair

1. Remove existing panel(s), prepare panel joint

faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

Refit

1. Fit 2 rear bolts securing body rear to chassis

and tighten to 45 Nm (33 lbf.ft).

2. Fit fuel tank.

FUEL DELIVERY SYSTEM - V8,

REPAIRS, Tank - fuel.

FUEL DELIVERY SYSTEM - Td5,

REPAIRS, Tank - fuel.

3. Fit cross member rear outer panel.

PANEL REPAIRS, REPAIRS, Cross

member outer rear panel.

4. Connect leads/multiplug to alternator.
5. Connect battery leads, negative lead last.

PANEL REPAIRS

REPAIRS 77-2-49

Cross member rear assembly

In this procedure, the cross member outer rear panel,
cross member closing rear panel, 'E' post assembly
and the panel body side assembly are replaced in
conjunction with the cross member rear assembly.

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove cross member closing rear panel.

PANEL REPAIRS, REPAIRS, Cross

member closing rear panel.

Repair

1. Remove existing panel(s), prepare panel joint

faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

Refit

1. Fit cross member closing rear panel.

PANEL REPAIRS, REPAIRS, Cross

member closing rear panel.

2. Connect leads/multiplug to alternator.
3. Connect battery leads, negative lead last.

Cross member rear assembly (RH/LH
section)

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove cross member closing rear panel.

PANEL REPAIRS, REPAIRS, Cross

member closing rear panel.

Repair

1. Remove existing panel(s), prepare panel joint

faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.

Refit

1. Fit cross member closing rear panel.

PANEL REPAIRS, REPAIRS, Cross

member closing rear panel.

2. Connect leads/multiplug to alternator.
3. Connect battery leads, negative lead last.

PANEL REPAIRS

77-2-50 REPAIRS

Rear floor complete assembly

Remove

1. Disconnect both battery leads, negative lead

first.

2. Disconnect leads/multiplug from alternator.
3. Remove loadspace carpet.

INTERIOR TRIM COMPONENTS,

REPAIRS, Carpet - loadspace.

4. Remove rear seats.

SEATS, REPAIRS, Seat - rear.

5. Remove rear carpet.

INTERIOR TRIM COMPONENTS,

REPAIRS, Carpet - rear.

6. Remove rear bumper assembly.

EXTERIOR FITTINGS, REPAIRS,

Bumper assembly - rear - up to 03MY.

7. Remove RH and LH mud flap and brackets.
8. Remove exhaust tail pipe heatshields.
9. Remove tread plates from rear door apertures.

10. Remove rear door aperture seal.
11. Remove tail door tread plate.
12. Remove loadspace carpet retainer.
13. Remove head lining rear trim finisher.
14. Remove tail door aperture seal.
15. Remove bolts securing body to chassis.
16. Remove relevant wiring from floor area.

Repair

M77 1712A

M77 1721A

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