Rear Frame Complete Replacement
2. Mass Production Body Welding Positions and Numbers - Remove

Rear Frame Upper Stiffener A/B and Rear Floor Upper Crossmember








Rear Floor Panel, Rear Floor Crossmember, and Jack-Up Stiffener



3. Construction - Remove

Rear Floor Upper Crossmember, Rear Frame Upper Stiffener A/B, Rear Floor Crossmember, and Jack-Up Stiffener

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 the rear floor upper crossmember, rear frame upper stiffener A/B (one side), and the upper stiffener bulkhead, and replace them.
Remove the rear floor crossmember and the jack-up stiffener, and replace them.


4. Mass Production Body Welding Positions and Numbers - Remove

Rear Frame Complete





5. Construction - Remove

Rear Frame 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.
Cut the outer panel, and remove the side sill extension end flange and the side sill reinforcement extension.
Remove the rear frame complete, and replace it.



NOTE:
Position the replacement parts.
Before doing the main welding, check the body dimensions:
?
Rear pillar gutter and rea panel positions
?
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 Complete - Weld
1.
Remove the side sill extension end flange (A) from the new rear frame complete (B).
2.
Clamp the new rear frame complete (A) to the body, and check it position. Weld the rear floor crossmember complete (B) and the rear crossmember extension (C).
3.
Weld rear frame A to the rear frame extension (B).
(?)*: 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)
4.
Weld the side sill extension (A) to the middle floor crossmember (B), the inside sill (C), and the front floor (D).
( )*: Welding positions with high-strength steel parts. Confirm the plug welding conditions.
5.
Weld the side sill extension (A) to the middle floor crossmember (B) and the rear wheelhouse (C).
( )*: Welding positions with high-strength steel parts. Confirm the plug welding conditions.
6.
Weld the spare tire pan upper crossmember (B) to the rear wheelhouse stiffener (C). Weld rear frame A and rear wheelhouse (D).
( )*: Welding positions with high-strength steel parts. Confirm the plug welding conditions.
7.
Weld the rear frame side outrigger (A) and the rear floor side panel (B) to the rear wheelhouse (C), the inner panel (D), and the outer panel (E).

2. Rear Floor Panel - Weld
1.
Attach the jack-up stiffener complete (A) to the spare tire pan crossmember (B) with the mounting bolts.
2.
Weld the new rear floor panel (B) to rear frame upper stiffener A, the middle floor crossmember (C), and the rear floor crossmember (D).
(?)*: Welding positions with rear frame upper stiffener A, include ultra high-strength steel (1500 MPa) parts.

Welding positions (E): 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).
3.
Weld the new rear floor panel (A) to rear frame upper stiffener B and the jack-up stiffener complete (C).
(?)*: Welding positions with rear frame upper stiffener B, include ultra high-strength steel (1500 MPa) parts.

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).

3. Rear Frame Upper Stiffener A/B (One Side) and Rear Floor Upper Crossmember - Weld
1.
Weld new rear frame upper stiffener B and the upper stiffener bulkhead (C) to new rear frame upper stiffener A.
(?)*: Welding positions with rear frame upper stiffener A/B, 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)
2.
Weld the new rear floor upper crossmember (B) to rear frame upper stiffener A and the upper stiffener bulkhead (C).
(?)*: Welding positions with rear frame upper stiffener A, include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 15 in the table shown below.
Spot welding conditions
No. 15
9000 A
600 ms
3432 N (350 kgf)
3.
Weld the rear portion of rear frame upper stiffener A and rear frame upper stiffener B.
(?)*: Welding positions with rear frame upper stiffener A/B and rear frame A (C), 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 (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.
Weld the front portion of rear frame upper stiffener A.
(?)*: Welding positions with rear frame upper stiffener A and rear frame A (B), 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 (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).
( )*: Welding positions with high-strength steel parts. Confirm the plug welding conditions.
5.
Weld rear frame upper stiffener A/B to rear frame A (C) and the rear wheelhouse (D).
(?)*: Welding positions with rear frame upper stiffener A/B and rear frame A, include ultra high-strength steel (1500 MPa) parts.

Welding positions (E): 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).
6.
Weld the rear floor upper crossmember complete (B) to the rear floor panel (C), the rear floor crossmember (D), rear frame upper stiffener A, and the rear wheelhouse stiffener upper (E).
(?)*: Welding positions with rear frame upper stiffener A, include ultra high-strength steel (1500 MPa) parts.

Welding positions (F): 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. Side Sill Reinforcement Extension, Side Sill Extension End Flange, and Outer Panel - Weld
1.
Weld the new side sill reinforcement extension (A) to the side sill reinforcement (B) and the side sill extension (C).
(?)*: Welding positions with the side sill reinforcement, include ultra high-strength steel (1500 MPa) parts.

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).
2.
Weld the new side sill extension end flange (A) to the rear inner panel (B) and the side sill extension (C).
3.
Weld the new outer panel access window (A).
(?)*: Welding positions with the side sill reinforcement (B), include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 26 and 30 in the table shown below.
Spot welding conditions
No. 26
8000 A
800 ms
3432 N (350 kgf)
No. 30
8500 A
1200 ms
3432 N (350 kgf)