REPAIRS (page 28 of 34)

PANEL REPAIRS

77-2-48 REPAIRS

Cross member outer rear panel (centre 
section)

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 bumper assembly.

 + 

 EXTERIOR FITTINGS, REPAIRS, 

Bumper assembly - rear - up to 03MY. 

5. Remove rear folding step.

 + 

 EXTERIOR FITTINGS, REPAIRS, 

Rear folding step.

6. Remove exhaust tailpipe heatshield.
7. Remove tail door tread plate.
8. Remove head lining rear trim finisher.
9. Remove tail door aperture seal.

10. 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. 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.