Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Rear end Sheet Metal Repairs Rear Side Member Section (G1770933) - Installation

Land Rover Discovery (2009–2016) Service Manual / Body / Body Repairs and General Information / Rear end Sheet Metal Repairs Rear Side Member Section (G1770933) / Rear end Sheet Metal Repairs Rear Side Member Section (G1770933) - Installation

Installation

  1. Dress the flanges where necessary.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

  1. Using the old rear side member outer reinforcement and the measurements as a guide, cut the new rear side member outer reinforcement on the new rear side member service part as indicated.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

  1. Remove the spot welds and remove the rear side member outer reinforcement from the new rear side member as indicated.

CAUTION:

Care should be taken not to cut into the rear side member inner reinforcement when cutting the rear side member.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

Using the old rear side member outer section and the measurements as a guide, cut and detach the new rear side member section from the new rear side member service part as indicated.

CAUTION:

Care should be taken not to cut into the rear side member when cutting the rear side member inner reinforcement.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

  1. Using the old rear side reinforcement and the measurements as a guide, cut and detach the new rear side member inner reinforcement from the new rear side member service part as indicated.
  2. Clean and prepare the panel surfaces
  3. Offer up the new rear side member inner reinforcement and clamp into position. Check alignment if correct proceed to next step, if not, rectify and recheck before proceeding.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

  1. MIG weld the rear side member inner reinforcement butt joint as indicated.
  2. Dress the rear side member inner reinforcement MIG welded butt weld.
  3. Offer up the new rear side member section and clamp into position.

    Check alignment if correct proceed to next step, if not, rectify and recheck before proceeding.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

  1. MIG weld the rear side member section butt joint as indicated.
  2. Dress the rear side member section MIG welded butt weld.
  3. Offer up the new rear side member outer reinforcement and clamp into position. Check alignment if correct proceed to next step, if not, rectify and recheck before proceeding.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

  1. Tack MIG weld the rear side member outer reinforcement butt joint as indicated.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

  1. Drill holes where the MIG plug welds are to be installed as indicated.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

  1. Install the MIG plug welds as indicated.

Rear end sheet metal repairs rear side member section (G1770933) - Installation

  1. MIG weld the rear side member outer reinforcement butt joint as indicated.
  2. Dress the rear side member outer reinforcement MIG butt weld.
  3. Make sure that any open or exposed panel joints are correctly sealed.
  4. Make sure corrosion protection is applied to all areas affected by repair.
  5. The installation of associated panels and components is the reversal of removal procedure.
    next pageRear end Sheet Metal Repairs Rear Side Member Section (G1770933) - RemovalRear end Sheet Metal Repairs Rear Side Member Lower Side Extension (G1771166) / Removal and Installationnext page

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     Rear end Sheet Metal Repairs Rear Side Member Lower Side Extension (G1771166) / Removal and Installation

    REMOVAL NOTE: The rear side member lower side extension is installed in conjunction with: Rear bumper cover Rear bumper Back panel outer Back panel inner Rear lamp panel outer The rear side

     Rear end Sheet Metal Repairs Rear Side Member Closing Panel (G1780740) / Removal and Installation

    REMOVAL NOTE: The rear side member closing panel is installed in conjunction with: Rear bumper cover Rear bumper Rear lamp assembly Rear lamp panel outer Back panel outer Back panel inner Rear

     Rear end Sheet Metal Repairs Rear Lamp Panel Outer (G1771163)

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