Quarter Panel Replacement Cargo Van

The quarter panel service part is supplied as a complete panel and should be replaced as a complete panel only in the event the roof panel and upper side rail are to be replace. Sectioning procedures have been developed to allow the replacement of the quarter panel without the removal of the roof panel.

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove all related panels and components.
4. Visually inspect and repair as much of the damage as possible to factory specification. Refer to Dimensions - Body .

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coating.



6. Apply 50 mm (2 in) wide tape along the upper edge of the quarter panel (1) at the roof line.



7. Cut the quarter panel at the lower edge of the tape (1) to leave a 50 mm (2 in) wide flange of the original quarter panel attached to the side reinforcement rail (2).

Important: Do not damage any inner panels or reinforcements.

8. Locate, mark, and drill out all factory welds around the perimeter of the quarter panel as necessary to remove damaged panel. Note the number and location of welds for installation of the service panel.
9. Remove damaged quarter panel.

1. Trim and discard the upper mounting flange (1) on the service panel (2) so that it can fit over the 50 mm (2 in) tab left from the original panel.

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes 40 mm (1½ in) apart.




2. Remove the service part and drill 8 mm (5/16 in) holes for plug welding as noted from the original panel and along the sectioning (1) joint 13 mm (½ in) from the cut edge.
3. Install and position the modified service part according to body dimensions using three-dimensional measuring equipment.
4. Apply 3M Weld-Thru coating, P/N 05916 or equivalent, to all mating surfaces.
5. Plug weld accordingly.
6. Use frequent measurements to ensure accurate fit and alignment to adjacent panels.
7. Apply 3M Ultra Pro Seam Sealer P/N 08361 or equivalent, to the sectioning joint.
8. Seal quarter panel at the floor seam.

Important: The quarter panel must be sealed at the floor to prevent exhaust gas intrusion into the vehicle.

9. Clean and prepare all welded surfaces.
10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
11. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
14. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.