Removal and Replacement

Remove, install rear door






MODEL
901.06 /36 /37 /46 /66 /67, 902.06 /07 /36 /37 /46 /47 /66 /67, 903.06 /07 /36 /37 /46 /47 /66 /67, 904.06 /36 /46 /66 except
CODE (W90) Delete item rear doors



Modification notes

Restore paint structure (touch up with brush) in adjustment area of hinges

Remove/install

1 Inspect door stop (8) on both door hinges replace if necessary
2 Release strap (5)
3 Inspect paint protective sheets (7) for damage replace if necessary
4 Remove screws (3, 4) attaching door hinges
5 Lift out rear door
The left rear door is removed in the same way
If the door is replaced, the seams must be sealed all round before painting

6 Install in the reverse order
7 Inspect alignment of rear door
Adjust if necessary

8 Remove door seal
9 Remove electric leads from repair area and cover
10 Remove miscellaneous detachable body components in repair area
11 Cover all detachable body components remaining in area to be repaired
12 Remove end plate (1)




Separating end plate
1 Cut spot welds out of end plate (1) (arrows).
2 Separate end plate (1) along both corner pillar panels (2) (dotted line, A).
Bore welding points.

Install

13 Straightening connecting plate, grinding off and coating with zinc dust paint Zinc dust paint suitable for spot welding
14 Prepare end plate (1) for installation




Preparing end plate for installation

1 Punch 6 mm dia. holes (1) (arrows) in end plate (1) at a maximum hole interval of 60 mm.
2 Grind end plate (1) in area of punched holes and in area (4) and coat with zinc dust paint.
3 Fit end plate (1), align and clamp.
Zinc dust paint suitable for spot welding

15 Weld in end plate (1)
1 Weld end plate (1) to cross member (3) at top ( , arrows).
2 Weld end plate (1) to corner paneling (2) ( , A)
3 Spot weld end plate (1) at bottom to cross member ( , arrows).

16 Grind down extending welding material
17 Vacuum out hollow cavities
Metal filings or metallic grinding dust in cavities can lead to corrosive damage.
Wet/dry vacuum cleaner

18 Clean areas to be repaired with MOPAR primer/filler or equivalent
19 Supplement standard seals with MOPAR body sealant or equivalent
Seam sealing after repairs
20 Add MOPAR permanent underfloor or equivalent protection as a supplement to underbody protection installed as standard
21 Paint repair area and adjacent surfaces
22 Seal hollow cavities on right and left in end plate (1) with assembly foam
Perform step to ensure that no exhaust gases get into the passenger compartment through the openings in the rear panel while driving

Sealing left and right hollow cavities in end plate with assembly foam




1 Install assembly foam through second opening (arrow) on right and left in end plate (1) in front of sealing plates (4).

Screw screws into towing hook mount on right side, to keep glue off of threads When replacing end cross member new sealing plates (4) are not delivered, therefore completely foam area between opening A and B.

2 Allow assembly foam to harden as described and remove excessive material.
Assembly foam

23 Supplement cavity preservation
24 Install rear doors
25 Install rear wooden floor
26 Install door seal
27 Install cover rail for wooden floor
28 Connect electrical leads to body
29 Install tailgate step Only with code MBZ, tailgate step
30 Install rear bumper
31 Install trailer coupling Only on vehicles with trailer coupling
32 Install spare wheel
33 Reinstall miscellaneous detachable body components