Orlando

Underbody Rear Side Rail Sectioning — Brazing

Note : According to different corrosion warranties, only the regional mandatory joining methods are allowed.

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

Warning : Refer to Collision Sectioning Warning in the Preface section.

Warning : Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .



6. Create cut lines on the underbody rear side rail (1).



7. Cut the underbody rear side rail (1) where sectioning is to be performed.

Note : Do not damage any other panels or reinforcements.




8. Locate and mark all the necessary factory welds of the underbody rear side rail (1).
9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



10. Remove the damaged underbody rear side rail (1).

1. Cut the underbody rear side rail (1) in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
2. Prepare all mating surfaces as necessary.
3. Align the underbody rear side rail.



4. Create 6 x 20 mm (4/16 x 12/16 in) slots for brazing along the edges of the underbody rear side rail (1) as noted from the original panel.
5. Clean and prepare the attaching surfaces for brazing.



6. Position the underbody rear side rail (1) on the vehicle.
7. Verify the fit of the underbody rear side rail.
8. Clamp the underbody rear side rail into position.



9. Braze the underbody rear side rail (1) accordingly.
10. To create a solid stitch braze with minimum heat distortion, make 25 mm (1 in) stitch brazes along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch braze.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
12. Paint the repaired area.
13. Install all related panels and components.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
15. Enable the SIR system. Refer to SIR Disabling and Enabling .