Rear Floor/Rear Frame Replacement

NOTE:

Rear frame A and rear frame upper stiffener B are made from ultra high-strength steel (UHSS) (1500 MPa). However, at the [X] and [Y] areas which are shown in the illustrations, each part is made from high-strength steel (except 1500 MPa).
For this reason, sectioning is possible at areas [X] and [Y]. Do not cut except the [X] and [Y] areas.



2. Mass Production Body Welding Positions and Numbers - Remove

Rear Frame Upper Stiffener B






Rear Floor Panel and Jack-Up Stiffener Complete



3. Construction - Remove

Rear Frame Upper Stiffener B, Rear Floor Panel, and Jack-Up Stiffener Complete

NOTE:
This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual.
The component replacement procedure described here is only for new genuine supplied parts, as needed, according to the area and the degree of damage on the body.
Remove rear frame upper stiffener B.
Cut and pry off the rear floor panel at the line beside both rear edges of rear frame upper stiffeners A, and replace it.
Check the jack-up stiffener crossmember position for damage. If necessary, replace the jack-up stiffener complete (the rear jack-up stiffener and the stiffener crossmember) and both of the spare tire pan crossmembers at the same time.


4. Mass Production Body Welding Positions and Numbers - Remove

Rear Floor Side Panel and Rear Frame A



5. Construction - Remove

Rear Floor Side Panel C and Rear Frame A, Rear Portion

NOTE:
This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual.
The component replacement procedure described here is only for new genuine supplied parts, as needed, according to the area and the degree of damage on the body.
Check the rear floor side panel position for damage. If necessary, replace it.
The rear portion of rear frame A may be sectioned. Refer to Parts Sectioning (Cut and Joint) Guidelines.
If the damage is limited to the rear portion of rear frame A, cut [Y] position of rear frame A, and replace it.
When replacing rear frame A, carefully remove the rear frame side outrigger from rear frame A.



NOTE:
Position the replacement parts.
Before doing the main welding, check the body dimensions:
?
Rear panel position
?
Rear pillar gutter position
?
Tailgate opening
?
Front floor and rear floor, under view
?
Frame Repair chart
Temporarily install the related parts, then check for differences in level and clearance.
Check the external parts fitting positions. Make sure the body lines flow smoothly.
Confirm the sheet thickness, tensile strength, and existence of the zinc treatment of both sides, and set the welder to conform to the welding conditions by referring to Roof and Side Panel Construction and Floor and Rear Body Construction.
Welding symbols (The welding symbols with dashed lines have a meaning of the spot welding of the part which is not visible)
( ) and ( )*: The number of welds

1. Rear Frame A, Rear Portion - Weld
1.
Weld the rear portion of new rear frame A and the body side rear frame A (B).
L*: Welding positions with high-strength steel parts. Confirm the butt welding conditions.
2.
Weld the rear frame side outrigger (B) to rear frame A.

(?)*: Welding positions with rear frame A, include ultra high-strength steel (1500 MPa) parts.

Welding positions (C): Must be welded according to the following conditions.
Plug hole diameter: ?10 mm (0.39 in)
Welding wire: Must use wire with a tensile strength of 980 MPa or higher (142 ksi or higher).

2. Rear Floor Side Panel - Weld
1.
Weld the rear floor side panel (C) to rear frame A, the rear frame side outrigger (B), the rear wheelhouse (D), the wheelhouse upper patch (E), and the outer panel (F).
(?)*: Welding positions with rear frame A, include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 12 in the table shown below.
Spot welding conditions
No. 12
7500 A
600 ms
3432 N (350 kgf)

3. Jack-Up Stiffener Complete - Weld
1.
Temporarily install both of the new spare tire pan crossmembers (A) to the new jack-up stiffener complete (B) with subframe stay mounting bolts (C), and set and clamp them to the body.
Check the jack-up stiffener complete positions, and tighten the bolts.
2.
Weld thespare tire pan crossmembers (B) to rear frames A and the spare tire pan lower crossmembers (C) on both sides.
(?)*: Welding positions with rear frame A, include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 13 in the table shown below.
Spot welding conditions
No. 13
8000 A
600 ms
3432 N (350 kgf)

Welding positions (D): Must be welded according to the following conditions.
Plug hole diameter: ?10 mm (0.39 in)
Welding wire: Must use wire with a tensile strength of 980 MPa or higher (142 ksi or higher).

4. Rear Floor Panel - Weld
1.
Cut the new rear floor panel (A) so it overlaps the body side rear floor panel (B) by about 40 mm (1.57 in). Insert the new rear floor panel between the body side rear floor panel and the jack-up stiffener complete (C), and clamp it.
2.
Drill the new rear floor panel (A) through holes at the joint for the body side rear floor panel (B) and the jack-up stiffener complete/spare tire pan crossmembers (C).
3.
Weld the new rear floor panel (B) to the body side rear floor panel (C), the jack-up stiffener complete (D), and both of the spare tire pan crossmembers (E). Weld the rear frame flange (F) to rear frame A.
(?)*: Welding positions with rear frame A, include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 13 in the table shown below.
Spot welding conditions
No. 13
8000 A
600 ms
3432 N (350 kgf)

5. Both Rear Frame Upper Stiffener B - Weld
1.
Weld rear frame upper stiffener B to rear frame A, the rear floor side panel (C), rear frame upper stiffener A (D), the rear frame flange (E), and the rear floor panel (F).
(?)*: Welding positions with rear frame A, include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 13 and 14 in the table shown below.
Spot welding conditions
No. 13
8000 A
600 ms
3432 N (350 kgf)
No. 14
8500 A
600 ms
3432 N (350 kgf)

Welding positions (G): Must be welded according to the following conditions.
Plug hole diameter: ?10 mm (0.39 in)
Welding wire: Must use wire with a tensile strength of 980 MPa or higher (142 ksi or higher).