Rocker Panel Replacement Outer

Important: When sectioning the outer rocker panel, do not section within 100 mm (4 in) of any other sectioning on adjacent components. Do not section the outer rocker panel within 100 mm (4 in) of either inner lower curve of the door opening frame. Sectioning in these areas could jeopardize the structural integrity of the vehicle.

The outer rocker panel is attached to the rear quarter panel and the side door opening frame with factory welds. The outer rocker panel must be removed before servicing the side door frame. When sectioning in an area with no reinforcement, a backing plate or sleeve must be used.

1. Remove all related panels and components.
2. Visually inspect the damaged areas.
3. Restore as much of the damage as possible to factory specifications.
4. Remove the sealers, the sound deadeners, and the anticorrosion materials as necessary.
5. Locate, mark and drill out factory welds as necessary. Note the number of welds for installation of the new assembly.
6. Measure, mark cut and remove the damaged section of the outer rocker panel, being careful in areas where there are multiple layers of steel.

Important: A gap 1 1/2 times the thickness of the metal (1) must be maintained at the joint between the old frame and replacement frame. Trim the replacement frame as required to achieve this fit.

1. Prepare the new door opening frame by measuring and cutting to match the removed section. Check for proper fit.



2. In areas having no inner reinforcements, cut pieces to serve as backing plates of the same configuration from the areas where sectioning is to be done. These should be approximately 75 mm (3 in ) in length. Use the damaged frame or the excess portions of the replacement frame.
3. Modify the pieces so they fit snugly to the backside of the section joints.



4. Pre-drill 5/16 in plug weld holes for installation of the new frame.



5. Fit the backing plate halfway into the section joint on the vehicle. Clamp and MIG weld the backing plate to the vehicle.
6. When all the backing plates are welded in place, reinstall the new part and check the fit using body dimensions.



7. When the replacement frame is properly fitted and aligned, clamp and MIG weld it to the backing plates. An alternating weld sequence is recommended to reduce heat and metal distortion.



8. MIG weld the remaining (1) weld hole to attach the panel permanently.
9. Clean and prepare welded surfaces.
10. Prime with two-part catalyzed primer.
11. Apply sealers and anti-corrosion materials as necessary.

Do not combine paint systems.

12. Install all the related panels and components.