Frelander 2. Manual - part 646

14. Cut through the adhesive to separate the reinforcements

from the roof panel.

15. Separate the remaining joints and remove the old panel.

Installation

1. Prepare the old and new panel joint surfaces.

2. Apply adhesive, in the areas illustrated.

3. Offer up the new panel and clamp into position. Check

alignment, if correct, proceed to next step, if not, rectify and

recheck before proceeding.

4. Install 10 21mm bolts.

5. NOTE: Along the RH and LH sides of the panel, spot welds

should be installed adjacent to the originals and not in the

same locations.

Spot weld.

6. Dress all welded joints.
7. The installation of associated panels and mechanical

components is the reverse of removal.

Roof Sheet Metal Repairs - Roof Front PanelVehicles With: Sliding Roof

Opening Panel

Removal and Installation

Removal

• NOTE: The roof front panel is serviced as a separate weld-on panel.

1. The roof front panel is replaced in conjunction with:

Windshield

Roof opening panel

2. For additional information relating to this repair procedure

please see the following:

For additional information, refer to: 

Body and Frame

 (501-26

Body Repairs - Vehicle Specific Information and Tolerance

Checks, Description and Operation) /

Standard Workshop Practices

 (100-00 General Information,

Description and Operation).

3. Disconnect both battery cables.
4. Remove the windshield glass.

For additional information, refer to: 

Windshield Glass

 (501-11

Glass, Frames and Mechanisms, Removal and Installation).

5. Remove both front seats.

For additional information, refer to: 

Front Seat

 (501-10

Seating, Removal and Installation).

6. Remove the roof opening panel.

For additional information, refer to: 

Roof Opening Panel

(501-17 Roof Opening Panel, Removal and Installation).

7. Remove both side air curtain modules.

For additional information, refer to: 

Side Air Curtain Module

(501-20B Supplemental Restraint System, Removal and

Installation).

8. Remove both front safety belt retractors.

For additional information, refer to: 

Front Safety Belt Retractor

(501-20A Safety Belt System, Removal and Installation).

9. Remove both rear safety belt retractors.

For additional information, refer to: 

Rear Safety Belt Retractor

(501-20A Safety Belt System, Removal and Installation).

10. Release and lay aside the wiring harness.

11. Remove 2 21mm headed bolts, 1 each side.

12. Mill out the spot welds.

13. Separate the joints and remove the old panel.

Installation

1. Prepare the old and new panel joint surfaces.

2. Apply adhesive, in the areas illustrated.

3. Offer up the new panel and clamp into position. Check

alignment, if correct, proceed to next step, if not, rectify and

recheck before proceeding.

4. Install 2 21mm bolts.