FRONT DOOR OUTER PANEL(for Double Cab) CUT AND JOIN REPLACEMENT SECTIONS

A01KXV5

  1. REMOVAL

    Symbol Meaning
    A01KY10 Remove Weld Points
    A01KXQ6 Cut and Join Location

    1. After grinding off the hemming location, remove the outer panel.

      A01KXRGC01
      *a Disc Sander *b Hemming Location

  2. INSTALLATION

    Symbol Meaning
    A01KXP7 Plug Weld
    A01KY6V Butt Weld
    A01KXY4 Spot MIG Weld
    A01KY5A Body Sealer

    1. Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts.

      Note

      Do not close the drain hole.

      Tech Tips

      Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement to make contact.

      A01KXOYC01
      *1 FRONT DOOR PANEL OUTER - -
      *a Drain Hole *b 10 mm (0.39 in.)

    2. Bend the flange hem with a wooden hammer and dolly.

      Tech Tips

      Bend the panel gradually so as not to distort it.

      A01KY1VC01
      *a Cloth Tape *b Dolly
      *c Wooden Hammer - -

    3. After welding, apply body sealer to the corresponding parts. (See the painting/coating)

    4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.