Rear End Panel Replacement LWB

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

Important: This panel is replaced at factory seams.

Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
4. Remove the rear impact bar. Refer to Rear Bumper Impact Bar Replacement .
5. Remove the rear impact bar bracket. Refer to Rear Bumper Bracket Replacement .
6. Remove the tail lights. Refer to Parking and Turn Signal Lamp Replacement .
7. Remove the spare wheel and emergency kit from the rear compartment.
8. Remove the rear lock striker. Refer to Rear Compartment Lid Latch Striker Replacement .
9. Remove the spare wheel and tyre carrier. Refer to Spare Wheel Carrier Replacement .
10. Repair as much of the damage as possible.
11. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Note the number and location of the factory welds for installation of the rear end panel.




12. Locate, mark and drill out the spot welds in the rear end panel assembly to the tail lamp filler panel. Repeat for opposite side.
13. Locate, mark and drill out the spot welds in the rear end panel assembly to the rear chassis rail. Repeat for opposite side.



14. Locate, mark and drill out the spot welds (1) of the rear end panel assembly to the side extension. Repeat for opposite side.
15. Remove the rear end panel.

1. Prepare all mating surfaces as necessary.



2. Weld (1) the rear end panel assembly to the side extension. Repeat for opposite side.



3. Weld (2) the rear end panel assembly to the rear chassis rail. Repeat for opposite side.
4. Weld (1) the rear end panel assembly to the tail lamp filler panel. Repeat for opposite side.
5. Clean all of the welded surfaces.
6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
7. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
8. Install the spare wheel and tyre carrier. Refer to Spare Wheel Carrier Replacement .
9. Install the rear lock striker. Refer to Rear Compartment Lid Latch Striker Replacement .
10. Install the tail lights. Refer to Parking and Turn Signal Lamp Replacement .
11. Install the rear impact bar. Refer to Rear Bumper Fascia Insert Replacement .
12. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
13. Install the spare wheel and emergency kit from the rear compartment.

Caution: Refer to Battery Disconnect Caution in the Preface section.

14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
15. Enable the SIR system. Refer to SIR Disabling and Enabling .

Rear End Panel Replacement SWB

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

Important: This panel is replaced at factory seams.

Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
4. Remove the rear impact bar. Refer to Rear Bumper Impact Bar Replacement .
5. Remove the rear impact bar bracket. Refer to Rear Bumper Bracket Replacement .
6. Remove the tail lights. Refer to Parking and Turn Signal Lamp Replacement .
7. Remove the spare wheel and emergency kit from the rear compartment.
8. Remove the rear lock striker. Refer to Rear Compartment Lid Latch Striker Replacement in Body Rear End.
9. Remove the spare wheel and tyre carrier. Refer to Spare Wheel Carrier Replacement .
10. Repair as much of the damage as possible.
11. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Note the number and location of the factory welds for installation of the rear end panel.




12. Locate, mark and drill out the spot welds in the rear end panel assembly to the tail lamp filler panel. Repeat for opposite side.
13. Locate, mark and drill out the spot welds in the rear end panel assembly to the rear chassis rail. Repeat for opposite side.



14. Locate, mark and drill out the spot welds (1) of the rear end panel assembly to the side extension. Repeat for opposite side.
15. Remove the rear end panel.

1. Prepare all mating surfaces as necessary.



2. Align the rear end panel assembly using the datum points (1) and (2) to the vehicle.



3. Weld (1) the rear end panel assembly to the side extension. Repeat for opposite side.



4. Weld (1) the rear end panel assembly to the rear chassis rail. Repeat for opposite side.
5. Weld the rear end panel assembly to the tail lamp filler panel. Repeat for opposite side.
6. Clean and prepare all of the welded surfaces.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
9. Install the spare wheel and tyre carrier. Refer to Spare Wheel Carrier Replacement .
10. Install the rear lock striker. Refer to Rear Compartment Lid Latch Striker Replacement in Body Rear End.
11. Install the tail lights. Refer to Parking and Turn Signal Lamp Replacement .
12. Install the rear impact bar. Refer to Rear Bumper Fascia Insert Replacement .
13. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
14. Install the spare wheel and emergency kit from the rear compartment.

Caution: Refer to Battery Disconnect Caution in the Preface section.

15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
16. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.
17. If re-programming is required. Refer to Control Module References .