501-29 Funilaria lateral

501-29-1 Side Panel Sheet Metal Repairs 501-29-1 . SECTION 501-29 Side Panel Sheet Metal Repairs VEHICLE APPLICATION: 2011.50 Ranger CONTENTS REMOVAL AND INSTALLATION A-Pillar Outer Panel............................................................................................................ A-Pillar Assembly................................................................................................................ Rocker Panel – Double Cab............................................................................................. Rocker Panel – Single Cab............................................................................................... Rocker Panel – Super Cab............................................................................................... Rocker Panel Inner Reinforcement – Double Cab............................................................ Rocker Panel Inner Reinforcement – Single Cab............................................................. Rocker Panel Inner Reinforcement – Super Cab.............................................................. B-Pillar and Reinforcement – Double Cab........................................................................ B-Pillar Outer Panel – Double Cab................................................................................... PAGE 501-29-2 501-29-11 501-29-15 501-29-20 501-29-26 501-29-32 501-29-36 501-29-40 501-29-44 501-29-56

501-29-2 Side Panel Sheet Metal Repairs 501-29-2 REMOVAL AND INSTALLATION A-Pillar Outer Panel General Equipment 6 mm Drill Bit Air Body Saw Hot Air Gun MIG/MAG Welding Equipment Resistance Spotwelding Equipment Removal 1. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. ‡ Windshield Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation). ‡ Front Door Refer to: Front Door (501-03 Body Closures, Removal and Installation). ‡ Door Hinges ‡ Weatherstrip ‡ A-pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Driver or passenger seat Refer to: Front Seat (501-10 Seating, Removal and Installation). ‡ Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation). ‡ Reposition the carpeting and the wiring harness away from the working area. 3. ‡ General Equipment: Air Body Saw General Equipment Spot weld drill Bit Materials Name Specification Windshield Adhesive Kit WSS-M11P57-A5

501-29-3 Side Panel Sheet Metal Repairs 501-29-3 REMOVAL AND INSTALLATION E140111 4. ‡ General Equipment: Spot weld drill Bit

501-29-4 Side Panel Sheet Metal Repairs 501-29-4 REMOVAL AND INSTALLATION E140112 5. ‡ General Equipment: Hot Air Gun

501-29-5 Side Panel Sheet Metal Repairs 501-29-5 REMOVAL AND INSTALLATION 170 E140113 Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation).

501-29-6 Side Panel Sheet Metal Repairs 501-29-6 REMOVAL AND INSTALLATION 3. ‡ General Equipment: 6 mm Drill Bit E140114 4. ‡ Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive

501-29-7 Side Panel Sheet Metal Repairs 501-29-7 REMOVAL AND INSTALLATION E140115 5. ‡ General Equipment: Resistance Spotwelding Equipment

501-29-8 Side Panel Sheet Metal Repairs 501-29-8 REMOVAL AND INSTALLATION E140116 6. ‡ General Equipment: MIG/MAG Welding Equipment

501-29- Side Panel Sheet Metal Repairs 501-29- REMOVAL AND INSTALLATION E140117

501-29-10 Side Panel Sheet Metal Repairs 501-29-10 REMOVAL AND INSTALLATION 7. ‡ Windshield Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation). ‡ Front Door Refer to: Front Door (501-03 Body Closures, Removal and Installation). ‡ Door Hinges ‡ Weatherstrip ‡ A-pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Driver or passenger seat Refer to: Front Seat (501-10 Seating, Removal and Installation). ‡ Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).

501-29-11 Side Panel Sheet Metal Repairs 501-29-11 REMOVAL AND INSTALLATION A-Pillar Assembly General Equipment 6 mm Drill Bit Hot Air Gun MIG/MAG Welding Equipment Resistance Spotwelding Equipment Removal General Equipment Spot weld drill Bit Materials Name Specification Windshield Adhesive Kit WSS-M11P57-A5

501-29-12 Side Panel Sheet Metal Repairs 501-29-12 REMOVAL AND INSTALLATION 1. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. ‡ Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Windshield Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation). ‡ Front Door Refer to: Front Door (501-03 Body Closures, Removal and Installation). ‡ Door Hinges ‡ Weatherstrip ‡ A-pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Driver or passenger seat Refer to: Front Seat (501-10 Seating, Removal and Installation). ‡ Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation). ‡ Reposition the carpeting and the wiring harness away from the working area. 3. ‡ General Equipment: Spot weld drill Bit E140136 4. ‡ General Equipment: Hot Air Gun 170 E140137

501-29-13 Side Panel Sheet Metal Repairs 501-29-13 REMOVAL AND INSTALLATION Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation). 3. ‡ General Equipment: 6 mm Drill Bit E140138 4. ‡ Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive E140139

501-29-14 Side Panel Sheet Metal Repairs 501-29-14 REMOVAL AND INSTALLATION 5. ‡ General Equipment: Resistance Spotwelding Equipment E140140 6. ‡ General Equipment: MIG/MAG Welding Equipment E140141 7. ‡ Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Windshield Refer to: Windshield Glass (501-11 Glass, Frames and Mechanisms, Removal and Installation). ‡ Front Door Refer to: Front Door (501-03 Body Closures, Removal and Installation). ‡ Door Hinges ‡ Weatherstrip ‡ A-pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Driver or passenger seat Refer to: Front Seat (501-10 Seating, Removal and Installation). ‡ Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).

501-29-15 Side Panel Sheet Metal Repairs 501-29-15 REMOVAL AND INSTALLATION Rocker Panel – Double Cab General Equipment Air Body Saw Hot Air Gun MIG/MAG Welding Equipment Resistance Spotwelding Equipment Removal 1. ‡ Refer to: Front Door (501-03 Body Closures, Removal and Installation). Refer to: Rear Door - Double Cab (501-03 Body Closures, Removal and Installation). Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Cowl Side Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Front Seat (501-10 Seating, Removal and Installation). Refer to: Rear Seat (501-10 Seating, Removal and Installation). ‡ Remove the load body from the vechicle. ‡ Reposition the carpeting and the wiring harness away from the working area. 2. ‡ General Equipment: Air Body Saw General Equipment Spot weld drill Bit Materials Name Specification Windshield Adhesive Kit WSS-M11P57-A5

501-29-16 Side Panel Sheet Metal Repairs 501-29-16 REMOVAL AND INSTALLATION E139677 3. ‡ General Equipment: Spot weld drill Bit E139678

501-29-17 Side Panel Sheet Metal Repairs 501-29-17 REMOVAL AND INSTALLATION 4. ‡ General Equipment: Hot Air Gun 170 E139679 Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). E139680 4. ‡ General Equipment: MIG/MAG Welding Equipment 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation). 3. ‡ Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive

501-29-18 Side Panel Sheet Metal Repairs 501-29-18 REMOVAL AND INSTALLATION E139681 5. ‡ General Equipment: Resistance Spotwelding Equipment E139682

501-29-19 Side Panel Sheet Metal Repairs 501-29-19 REMOVAL AND INSTALLATION 6. ‡ Refer to: Front Door (501-03 Body Closures, Removal and Installation). Refer to: Rear Door - Double Cab (501-03 Body Closures, Removal and Installation). Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Cowl Side Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Front Seat (501-10 Seating, Removal and Installation). Refer to: Rear Seat (501-10 Seating, Removal and Installation). ‡ Install the load body into the vechicle.

501-29-20 Side Panel Sheet Metal Repairs 501-29-20 REMOVAL AND INSTALLATION Rocker Panel – Single Cab General Equipment Air Body Saw Hot Air Gun MIG/MAG Welding Equipment Resistance Spotwelding Equipment Removal 1. ‡ Door Hinges ‡ Front and Rear Door ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ A- B- and C-Pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 4-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation). ‡ Reposition the carpeting and the wiring harness away from the working area. 2. ‡ General Equipment: Air Body Saw General Equipment Spot weld drill Bit Materials Name Specification Windshield Adhesive Kit WSS-M11P57-A5

501-29-21 Side Panel Sheet Metal Repairs 501-29-21 REMOVAL AND INSTALLATION 35 mm 25 mm E112744 3. ‡ General Equipment: Spot weld drill Bit E112745 460 mm

501-29-22 Side Panel Sheet Metal Repairs 501-29-22 REMOVAL AND INSTALLATION 4. ‡ General Equipment: Hot Air Gun E112746 5. ‡ General Equipment: Hot Air Gun E112747 170 170

501-29-23 Side Panel Sheet Metal Repairs 501-29-23 REMOVAL AND INSTALLATION Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). E112748 4. ‡ General Equipment: MIG/MAG Welding Equipment 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation). 3. ‡ Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive

501-29-24 Side Panel Sheet Metal Repairs 501-29-24 REMOVAL AND INSTALLATION E112749 5. ‡ General Equipment: Resistance Spotwelding Equipment E112788 6. E112789

501-29-25 Side Panel Sheet Metal Repairs 501-29-25 REMOVAL AND INSTALLATION 7. ‡ Door Hinges ‡ Front and Rear Door ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ A- B- and C-Pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 4-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation).

501-29-26 Side Panel Sheet Metal Repairs 501-29-26 REMOVAL AND INSTALLATION Rocker Panel – Super Cab General Equipment Air Body Saw Hot Air Gun MIG/MAG Welding Equipment Resistance Spotwelding Equipment Removal 1. ‡ Front and Rear Door ‡ Door Hinges ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ Refer to: A-Pillar Trim Panel (501-05, Removal and Installation). Refer to: B-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation). ‡ Reposition the carpeting and the wiring harness away from the working area. 2. ‡ General Equipment: Air Body Saw General Equipment Spot weld drill Bit Materials Name Specification Windshield Adhesive Kit WSS-M11P57-A5

501-29-27 Side Panel Sheet Metal Repairs 501-29-27 REMOVAL AND INSTALLATION 35 mm 25 mm E108797 3. ‡ General Equipment: Spot weld drill Bit E108798 460 mm

501-29-28 Side Panel Sheet Metal Repairs 501-29-28 REMOVAL AND INSTALLATION 4. ‡ General Equipment: Hot Air Gun E108799 5. ‡ General Equipment: Hot Air Gun E108800 170 170

501-29-29 Side Panel Sheet Metal Repairs 501-29-29 REMOVAL AND INSTALLATION Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). E108801 4. ‡ General Equipment: MIG/MAG Welding Equipment 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation). 3. ‡ Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive

501-29-30 Side Panel Sheet Metal Repairs 501-29-30 REMOVAL AND INSTALLATION E108802 5. ‡ General Equipment: Resistance Spotwelding Equipment E108803

501-29-31 Side Panel Sheet Metal Repairs 501-29-31 REMOVAL AND INSTALLATION 6. E108804 7. ‡ Front and Rear Door ‡ Door Hinges ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ Refer to: A-Pillar Trim Panel (501-05, Removal and Installation). Refer to: B-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation).

501-29-32 Side Panel Sheet Metal Repairs 501-29-32 REMOVAL AND INSTALLATION Rocker Panel Inner Reinforcement – Double Cab General Equipment Air Body Saw MIG/MAG Welding Equipment Removal 1. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. ‡ Refer to: A-Pillar Assembly (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Rocker Panel ‡ Door Hinges ‡ Front and Rear Door ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ A- B- and C-Pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation). ‡ Reposition the carpeting and the wiring harness away from the working area. 3. ‡ General Equipment: Air Body Saw General Equipment Resistance Spotwelding Equipment Spot weld drill Bit

501-29-33 Side Panel Sheet Metal Repairs 501-29-33 REMOVAL AND INSTALLATION E115412 4. ‡ General Equipment: Spot weld drill Bit E115413 Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation). 3. ‡ General Equipment: Resistance Spotwelding Equipment

501-29-34 Side Panel Sheet Metal Repairs 501-29-34 REMOVAL AND INSTALLATION E115414 4. ‡ General Equipment: MIG/MAG Welding Equipment E115415

501-29-35 Side Panel Sheet Metal Repairs 501-29-35 REMOVAL AND INSTALLATION 5. ‡ Refer to: A-Pillar Assembly (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Rocker Panel ‡ Door Hinges ‡ Front and Rear Door ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ A- B- and C-Pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation).

501-29-36 Side Panel Sheet Metal Repairs 501-29-36 REMOVAL AND INSTALLATION Rocker Panel Inner Reinforcement – Single Cab General Equipment Air Body Saw MIG/MAG Welding Equipment Removal 1. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. ‡ Refer to: A-Pillar Assembly (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Rocker Panel ‡ Door Hinges ‡ Front and Rear Door ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ A- B- and C-Pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation). ‡ Reposition the carpeting and the wiring harness away from the working area. 3. ‡ General Equipment: Air Body Saw General Equipment Resistance Spotwelding Equipment Spot weld drill Bit

501-29-37 Side Panel Sheet Metal Repairs 501-29-37 REMOVAL AND INSTALLATION E115412 4. ‡ General Equipment: Spot weld drill Bit E115413 Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation). 3. ‡ General Equipment: Resistance Spotwelding Equipment

501-29-38 Side Panel Sheet Metal Repairs 501-29-38 REMOVAL AND INSTALLATION E115414 4. ‡ General Equipment: MIG/MAG Welding Equipment E115415

501-29-39 Side Panel Sheet Metal Repairs 501-29-39 REMOVAL AND INSTALLATION 5. ‡ Refer to: A-Pillar Assembly (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Rocker Panel ‡ Door Hinges ‡ Front and Rear Door ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ A- B- and C-Pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation).

501-29-40 Side Panel Sheet Metal Repairs 501-29-40 REMOVAL AND INSTALLATION Rocker Panel Inner Reinforcement – Super Cab General Equipment Air Body Saw MIG/MAG Welding Equipment Removal 1. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. ‡ Refer to: A-Pillar Assembly (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Rocker Panel ‡ Door Hinges ‡ Front and Rear Door ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ A- B- and C-Pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation). ‡ Reposition the carpeting and the wiring harness away from the working area. 3. ‡ General Equipment: Air Body Saw General Equipment Resistance Spotwelding Equipment Spot weld drill Bit

501-29-41 Side Panel Sheet Metal Repairs 501-29-41 REMOVAL AND INSTALLATION E115412 4. ‡ General Equipment: Spot weld drill Bit E115413 Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation). 3. ‡ General Equipment: Resistance Spotwelding Equipment

501-29-42 Side Panel Sheet Metal Repairs 501-29-42 REMOVAL AND INSTALLATION E115414 4. ‡ General Equipment: MIG/MAG Welding Equipment E115415

501-29-43 Side Panel Sheet Metal Repairs 501-29-43 REMOVAL AND INSTALLATION 5. ‡ Refer to: A-Pillar Assembly (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Refer to: A-Pillar Outer Panel (501-29 Side Panel Sheet Metal Repairs, Removal and Installation). ‡ Rocker Panel ‡ Door Hinges ‡ Front and Rear Door ‡ Front Wheel Arch Trim ‡ Rear Wheel Arch Trim ‡ A- B- and C-Pillar Trim Refer to: A-Pillar Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: C-Pillar Trim Panel - 5-Door (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Rocker Panel Trim ‡ Refer to: Front Seat (501-10, Removal and Installation). Refer to: Rear Seat Cushion (501-10, Removal and Installation). Refer to: Rear Seat Backrest (501-10, Removal and Installation).

501-29-44 Side Panel Sheet Metal Repairs 501-29-44 REMOVAL AND INSTALLATION B-Pillar and Reinforcement – Double Cab General Equipment Air Body Saw Hot Air Gun MIG/MAG Welding Equipment Resistance Spotwelding Equipment Removal NOTE: Equipment: Measurement and alignment angle system 1. WARNING: High-strength steel (Usibor 1500) ‡ A suitably powerful resistance spot welding device with inverter technology must be used for this repair. Observe the manufacturer's welding equipment instructions and sub-section 501-25. ‡ The B-pillar reinforcement is made of high-strength steel plate (Usibor 1500). ‡ A partial replacement of the B-pillar reinforcement is not permissible. The required continuous MIG weld seam in the area of the cut causes structural changes which result in significant loss of strength in the B-pillar reinforcement. ‡ Due to its strength, the B-pillar reinforcement can not always be worked on with conventional body tools. ‡ Additional preparations are required for MIG puddle welding. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). General Equipment Spot weld drill Bit Materials Name Specification Windshield Adhesive Kit WSS-M11P57-A5 2. ‡ Rocker Panel Trim Refer to: Front Seat (501-10 Seating, Removal and Installation). Refer to: Rear Seat Cushion (501-10 Seating, Disassembly and Assembly). Refer to: Rear Seat Backrest (501-10 Seating, Disassembly and Assembly). Refer to: B-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Front and Rear Door ‡ Reposition the carpeting and the wiring harness away from the working area. 3. ‡ General Equipment: Air Body Saw General Equipment: Spot weld drill Bit

501-29-45 Side Panel Sheet Metal Repairs 501-29-45 REMOVAL AND INSTALLATION E140094 4. ‡ General Equipment: Hot Air Gun 170 E140095 5. ‡ General Equipment: Spot weld drill Bit

501-29-46 Side Panel Sheet Metal Repairs 501-29-46 REMOVAL AND INSTALLATION E140096 6. ‡ General Equipment: Air Body Saw 320 mm E140097 50 mm

501-29-47 Side Panel Sheet Metal Repairs 501-29-47 REMOVAL AND INSTALLATION 7. ‡ General Equipment: Air Body Saw E140098 8. ‡ General Equipment: Spot weld drill Bit General Equipment: Spot weld drill Bit

501-29-48 Side Panel Sheet Metal Repairs 501-29-48 REMOVAL AND INSTALLATION E140099 9. ‡ General Equipment: Spot weld drill Bit E140100

501-29-49 Side Panel Sheet Metal Repairs 501-29-49 REMOVAL AND INSTALLATION Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation). 3. ‡ ‡ The holes need to be pre-milled with a spherical cutter with a small diameter. Afterwards these holes are then milled out to the required diameter with a spindle milling cutter. This method is essential in order to ensure that the material in the edge area of the milled holes is not weakened. Equipment: Spherical cutter ‡ Equipment: spindle milling cutter E140101

501-29-50 Side Panel Sheet Metal Repairs 501-29-50 REMOVAL AND INSTALLATION 4. ‡ WARNING: The B-pillar reinforcement is covered with a hot-dip aluminized coating on its entire surface. This coating needs to be fully ground off on the welding flanges on the front and rear using a fibre grinding disc. Any contamination due to parts of the coating in the welding bath will weaken the welded joint. E140102 5. ‡ WARNING: The A-pillar reinforcement is covered with a hot-dip aluminized coating on its entire surface. This coating needs to be fully ground off on the welding flanges on the front using a fibre grinding disc. Any contamination due to parts of the coating in the welding bath will weaken the welded joint. E140103 6. ‡ Resistance spot weld - Panel thickness 3 mm and greater! General Equipment: Resistance Spotwelding Equipment E140104

501-29-51 Side Panel Sheet Metal Repairs 501-29-51 REMOVAL AND INSTALLATION 7. ‡ General Equipment: MIG/MAG Welding Equipment E140105 8. ‡ Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive E140106 9. ‡ Puddle weld 2 panel layer. General Equipment: MIG/MAG Welding Equipment

501-29-52 Side Panel Sheet Metal Repairs 501-29-52 REMOVAL AND INSTALLATION E140107 10. ‡ Puddle weld 3 panel layer. General Equipment: MIG/MAG Welding Equipment

501-29-53 Side Panel Sheet Metal Repairs 501-29-53 REMOVAL AND INSTALLATION E140108 11. ‡ Resistance spot weld - Panel thickness 3 mm and greater! General Equipment: Resistance Spotwelding Equipment

501-29-54 Side Panel Sheet Metal Repairs 501-29-54 REMOVAL AND INSTALLATION E140109 12. ‡ General Equipment: MIG/MAG Welding Equipment E140110

501-29-55 Side Panel Sheet Metal Repairs 501-29-55 REMOVAL AND INSTALLATION 13. ‡ Rocker Panel Trim Refer to: Front Seat (501-10 Seating, Removal and Installation). Refer to: Rear Seat Cushion (501-10 Seating, Disassembly and Assembly). Refer to: Rear Seat Backrest (501-10 Seating, Disassembly and Assembly). Refer to: B-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: Headliner (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Front and Rear Door

501-29-56 Side Panel Sheet Metal Repairs 501-29-56 REMOVAL AND INSTALLATION B-Pillar Outer Panel – Double Cab General Equipment Air Body Saw Hot Air Gun MIG/MAG Welding Equipment Resistance Spotwelding Equipment Removal 1. ‡ Rocker Panel Trim Refer to: Front Seat (501-10 Seating, Removal and Installation). Refer to: B-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Front and Rear Door ‡ Reposition the carpeting and the wiring harness away from the working area. 2. ‡ General Equipment: Air Body Saw General Equipment: Spot weld drill Bit E139810 General Equipment Spot weld drill Bit Materials Name Specification Windshield Adhesive Kit WSS-M11P57-A5

501-29-57 Side Panel Sheet Metal Repairs 501-29-57 REMOVAL AND INSTALLATION 3. ‡ General Equipment: Hot Air Gun E139811 Installation 1. NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the manufacturer's welding equipment instructions and sub-section 501-25 must be followed. Refer to: Tools and Equipment for Body Repairs (501-25 Body Repairs - General Information, Description and Operation). 170 2. NOTE: Sealer or adhesive must not be applied in welding zones. Areas which were bonded or sealed needs to be thoroughly sealed afterwards. Refer to: Sealer, Underbody Protection Material and Adhesives (501-25 Body Repairs - General Information, Description and Operation). 3. ‡ Material: Windshield Adhesive Kit (WSS-M11P57-A5) adhesive

501-29-58 Side Panel Sheet Metal Repairs 501-29-58 REMOVAL AND INSTALLATION E139812 4. ‡ Resistance spot weld - Panel thickness 3 mm and greater! General Equipment: Resistance Spotwelding Equipment

501-29-59 Side Panel Sheet Metal Repairs 501-29-59 REMOVAL AND INSTALLATION E139813 5. ‡ General Equipment: MIG/MAG Welding Equipment E139814

501-29-60 Side Panel Sheet Metal Repairs 501-29-60 REMOVAL AND INSTALLATION 6. ‡ Rocker Panel Trim Refer to: Front Seat (501-10 Seating, Removal and Installation). Refer to: B-Pillar Upper Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). Refer to: B-Pillar Lower Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation). ‡ Front and Rear Door