Front Strut / Shock Tower: Service and Repair

Mass Production Body Welding Diagram




The front wheelhouse component is constructed as a unit with the front damper housing. Therefore, replacement of the component affects the front wheel alignment. When assembling it, either use a positioning jig or follow the dimensions on the frame repair chart for positioning. Weld carefully.

Replacement

1. Remove the related parts.
- Parts that must be removed when removing the front bulkhead
- Parts on passenger side of lower dashboard which are especially flammable.
- Electrical accessories in engine the compartment and the wire harnesses.

2. Pull out and straighten the damaged area to approximately the original shape.
- Attach the vehicle to the frame straightener by tightening the underbody clamps at the horizontal pinch weld points.
- Before cutting off the damaged sections, pull them out so that they are restored to the original shape.
- Do not pull out more than necessary.
- Pull out and straighten the damaged area of the lower dashboard, front pillar, and other parts.
- After pulling, check the damper housing position using the body dimensional drawings and positioning jig.

NOTE: Check the condition of the door and hinges.

3. Peel off the undercoat.
Heat the undercoat at the weld areas of the wheelhouse and front side frame with a gas torch, and peel off the undercoat with a metal spatula.
4. Remove the wheelhouse upper member.
- Center punch around the spot weld imprints.
- Use the special spot cutter to drill holes at the spot weld nuggets.
- Remove the MIG weld flange with a disc sander.

WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

- Using a chisel, pry off the welded flange from the front pillar and damper housing.






NOTE: Remove the wheelhouse upper member carefully so it can be reused.

5. Replace the front wheelhouse




- Center punch around the spot weld imprints on the front side frame and damper housing.
- Drill holes in the center punched areas using a spot cutter.
- Using a chisel, pry off the welded flange.
- Level and finish the burrs left on the welding surfaces with a sander.

6. Check the damper housing for position and damage. If necessary, replace the damper housing.




- Center punch around the spot weld imprints on the front side frame, lower dashboard, and dashboard upper side member.
- Drill holes using a spot cutter.
- Using a chisel, pry off the weld flange.
- From the passenger compartment side, drill holes in the spot welded area with a 5 mm (0.2 in.) spot weld cutter.






NOTE: Drill holes completely through the parts since the replacement damper housing will be welded by MIG welding.

7. Straighten the related parts.




- Level and finish the burrs left on the welding surfaces with a sander.
- Fill all drilled holes by MIG or gas welding.
- Use a hammer and dolly to even out the welded areas of the lower dashboard, front side frame and dashboard, upper side member.

8. Set the new front wheelhouse and damper housing.
- Apply body paint to both sides of the new front wheelhouse and damper housing.
- See Paint Repair section.

WARNING:
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening the paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection, and appropriate clothing when painting.
- Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.

- Remove the undercoat from both sides of the welding section and expose the steel plate using a disc sander.

WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting, or grinding.

- Clamp the front side frame with vise-grips and squill vises.

NOTE: Apply the spot sealer to the welding surface when spot welding.

- Clamp the front bulkhead with vise-grips.
- Measure the front compartment diagonally.






NOTE: Use of a positioning jig is recommended.

- Spot weld several points in the clamped sections, and temporarily attach the front wheelhouse and damper housing.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.




9. Check the dimensions, temporarily install the hood, front fender and headlight, and check for differences in level and clearance.
10. Perform the main welding.
- Weld as much as possible with the jig still mounted.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

- Make 20% to 30% more spot welds than there were holes drilled.









NOTE: If there isn't room for spot welds, compensate by using MIG welds.




- Plug weld the holes in the lower dashboard and damper housing with a MIG welder.




11. After the front bulkhead has been welded, weld the wheelhouse upper member.
If the upper member is to be reused, make MIG plug welds at the drilled holes.

12. Finish the welded area. Use a hammer and dolly to even out the side bulkhead and front side frame flanges for a close fit with the surface of the front wheelhouse and damper housing.
13. Apply sealer to the mating surface of the lower dashboard and front side frame, etc.
14. Apply the paint.

WARNING:
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening the paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection, and appropriate clothing when painting.
- Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.

15. Apply the undercoat. Undercoat the front floor, etc, and apply anti-rust agent to the inside of the welding section of the front side frame, lower dashboard, and upper member, etc.
16. Install in the parts in the reverse order in which they were removed.
17. Inspect, check, and make adjustments.
- Measure the front wheel alignment.
- Inspect the brake system.
- Adjust the headlight aim.