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Bolted-On Exterior Panels - Part 2 (EXT04e) Textbook Version: 5.2 © 2003 - 2014 Inter-Industry Conference On Auto Collision Repair EXT04e-INMAN1-E

ExteriorPanels- Bolted-On Textbook Part2(EXT04e)

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Bolted-OnExterior�Panels�-Part�2�(EXT04e)

Textbook

Version:�5.2

©�2003�-�2014�Inter-Industry�Conference�On�Auto�Collision�Repair

EXT04e-INMAN1-E

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Bolted-On�Exterior�Panels�-�Part�2�(EXT04e)Textbook

Table�of�Contents 3

Contents

Introduction..............................................................................................................................7Obligations�To�The�Customer�And�Liability.......................................................................... 7

Module�1�-�Front�Body�Panels................................................................................................13Bumper�Assemblies.............................................................................................................13Steel�Bumpers.....................................................................................................................19Grilles................................................................................................................................. 22Fenders............................................................................................................................... 24Activity:�Fender�Adjustment................................................................................................27Hoods................................................................................................................................. 28Activity:�Hood�Adjustment..................................................................................................35Module�Wrap-Up............................................................................................................... 36

Module�2�-�Rear�Body�Panels.................................................................................................39Truck�Box........................................................................................................................... 39Deck�Lid.............................................................................................................................41Liftgates�And�Hatches......................................................................................................... 44Tailgates.............................................................................................................................. 46Module�Wrap-Up............................................................................................................... 48

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Introduction

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IntroductionTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 7

Obligations�To�The�Customer�And�Liability

The�collision�repair�industry�has�anobligation�to�correctly�repair�thecustomer’s�vehicle.�Collision�repairs�mustbe�performed�using:

• recommended�or�testedprocedures�from�vehicle�makers,I-CAR,�and�other�research�andtesting�organizations.

• quality�replacement�parts�andmaterials.

• repair�processes�and�parts�aswritten�and�agreed�upon�in�therepair�order.�If�items�on�the�repairagreement�are�not�consistentwith�the�repair�order,�it�can�beconsidered�fraud.

Performing�proper�collision�repairsrequires�using�parts�and�procedures�thatkeep�remaining�warranties�intact.

Collision�repairs�must�restore:

• safety.• structural�integrity.• durability.• performance.

• fit.• finish.

Throughout�the�damage�analysis�andrepair�process�the�repairer�and�insurermust:

• communicate�with�each�other.• maintain�constant�communication

with�the�customer.• be�in�agreement�with�each�other

and�the�customer�on�how�repairswill�be�performed.

• inform�the�customer�of�anychanges�in�the�repair�plan�fromthe�original�repair�agreement,�andexplain�the�changes�and�why�theyhave�to�be�made.

To�reduce�liability:

• make�sure�that�all�repairs�areperformed�thoroughly,�correctlyand�as�listed�in�the�damage�report.

• follow�proper�procedures.• have�documentation�of�required

repairs�with�detailed�recordkeeping�available�for�customers.

IntroductionTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 8

Technicians�are�considered�theexperts�and�are�expected�to�beknowledgeable�on�how�to�performa�quality�repair.

Liability�insurance�that�covers�the�repairfacility�may�not�always�cover�all�damages.For�example:

• the�policy�may�not�coverfaulty�repairs,�leaving�liabilityresponsibility�completely�on�thefacility.

• a�shop�owner�may�find�that�repairfacility�liability�coverage�may�notcover�the�full�amount�awarded�ina�lawsuit.�The�shop�owner�wouldhave�to�pay�the�difference.

It�is�difficult�to�reduce�the�risk�of�liabilityexposure.�The�part�that�the�repairer�cancontrol�is�the�chance�of�being�found�atfault.�Chances�can�be�minimized�by:

• using�recommended�or�testedprocedures�from�the�vehiclemakers,�I-CAR,�or�other�researchand�testing�organizations.

• using�quality�replacement�partsand�materials�that�restore�fit,

finish,�durability,�and�perform�atleast�as�well�as�the�original.

• keeping�thorough�records.

Keeping�thorough�records�includes�morethan�recording�the�date,�mileage,�and�pre-existing�damage.�Record�keeping�alsoincludes:

• making�sure�all�notes�are�legible.• verifying�the�repairs�that�were

made�or�not�made.• having�the�customer�sign�a

waiver�for�repairs�that�they�donot�want�performed.�Repairersmust�determine�their�liability�onnot�repairing�safety�systems�suchas�restraint�and�anti-lock�brakesystems.

• keeping�computer�printouts�orworksheets�on�file�showing�wheelalignment�readings�or�vehicledimensions�before�and�afterrepairs.

• keeping�scan�tool�printouts�andrecords�of�computer�codes�forairbag,�anti-lock�brake,�emission,and�powertrain�control�module(PCM)�systems.

IntroductionTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 9

• attaching�the�OEM�or�other�testedprocedure�printout�to�the�vehiclerepair�order.

• keeping�receipts�for�all�subletwork�performed.

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Module�1�-�FrontBody�Panels

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Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 13

Bumper�Assemblies

Learning�objectives�for�this�moduleinclude:

• identifying�bumper�systems.• replacing�steel�bumpers.• replacing�plastic�bumper�covers�/

fascias.• replacing�energy�absorbers.• replacing�bumper�reinforcements.• replacing�grilles.• replacing�steel�fenders.• aligning�fenders.• replacing�hoods.• aligning�hoods.

These�are�the�various�parts�of�a�bumper�assembly.

Many�of�today's�bumper�assembliesare�designed�to�withstand�very�minorcollisions�with�limited�damage�tothe�vehicle.�In�a�moderate�to�severecollision,�bumper�assemblies�assist�incollision�energy�management�throughthe�use�of�energy�absorbers�and�bumperreinforcements.�It�may�be�difficult�to�makea�complete�damage�analysis�of�a�bumperassembly�during�initial�inspection�due�todamage�that�may�be�hidden�behind�thefascia�or�bumper�cover.

Some�bumper�assemblies�include�a�plastic�bumpercover.

The�bumper�assembly�on�this�vehicle�is�acombination�of�steel�and�plastic.

Bumper�assemblies,�like�those�foundon�unibody�and�some�body-over-framevehicles,�are�typically�made�up�of:

• a�plastic�bumper�cover�or�fascia.• one�or�two�energy�absorbers.• a�bumper�reinforcement.

Some�bumper�covers�and�grilles�are�oneassembly.

Bumper�assembly�types�include:

• a�combination�of�steel�and�plastic.This�may�include�a�painted�steel

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 14

bumper�with�a�plastic�fasciaattached�below�it.

• plastic�bumper�covers�or�fascias.These�have�a�plastic�bumpercover�over�an�energy�absorberand�bumper�reinforcement.Bumper�reinforcements�may�bemade�of�ultra-high-strength�steel(UHSS),�aluminum,�or�a�reinforcedcomposite.

This�bumper�has�a�plastic�air�dam�attached�to�it.

When�replacing�a�complete�or�partialbumper�assembly,�it�may�be�necessary�toremove�some�adjacent�parts.�These�mayinclude,�but�are�not�limited�to:

• grilles�or�grille�inserts.• headlamps�and�driving�lamps.

Headlamps�may�have�to�beremoved�to�access�fasteners.�Ifa�driving�lamp�is�installed�ona�bumper�assembly,�it�may�notrequire�removal,�but�will�haveto�be�disconnected�for�bumperremoval.

• air�dams.• the�fender.�Complete�removal

may�not�be�required,�but�partial

removal�may�be�necessary�toaccess�hidden�fasteners.

Replacement�plastic�bumper�covers�will�requirerefinishing�before�installation.

Bumper�covers:

• are�usually�made�of�some�type�ofplastic.�Some�are�refinished�bythe�vehicle�maker,�and�some�arecolor-impregnated.

• are�cosmetic.�Although�bumpercovers�may�have�some�energyabsorbing�qualities,�they�aretypically�a�cosmetic�panel.

• are�designed�to�allow�for�airflowinto�the�engine�compartment.

• may�have�lamps�attached.• will�usually�require�removal�for

a�two-sided�repair.�Even�if�thebackside�has�limited�access,�itmay�be�beneficial�to�remove�thebumper�cover�for�repairs�andrefinishing.

• may�also�be�called�a�bumperfascia.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 15

A�rear�bumper�cover�may�have�attachments�such�aslamps.

Similar�to�front�bumper�covers,�rearbumper�covers�will�have�energy�absorbersand�a�bumper�reinforcement.�Otherconsiderations�for�rear�bumper�coversinclude:

• the�license�plate�mounting�areaand�lighting�associated�with�it.

• the�condition�of�the�step�pad�whenapplicable.

• verifying�attachment�locationsand�that�the�part�is�correct�forthe�vehicle�on�which�it�will�beinstalled.

Attachments�to�a�front�bumper�cover�may�include�anair�dam,�and�lamps.

Depending�on�the�vehicle,�some�bumperor�fascia�attachments�may�include:

• impact�strips.�Impact�strips�maybe�designed�into�a�bumpercover�to�reduce�damage�causedby�bumping�into�an�object.Impact�strips�are�the�25-50�mm(1"-2")�wide�strips�around�thebumper�cover�or�fascia.�Inspectthe�damaged�bumper�cover�todetermine�if�the�replacementpart�impact�strips�will�requirerefinishing.

• driving�or�fog�lamps.• grille�inserts.�Some�grilles�are

separate�from�the�bumper�cover,some�are�molded�into�the�bumpercover,�and�some�are�mechanicallyattached�to�the�bumper�cover.

• an�air�dam�or�air�deflectorunderneath�the�bumper�cover.

After�removing�this�bumper�cover,�any�hiddendamage�to�the�foam�energy�absorber�will�berevealed.

To�remove�a�front�or�rear�bumper�cover�orfascia:

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 16

• disconnect�any�wiring�that�isattached�to�the�bumper�cover.

• remove�any�required�attachmentsfor�access�to�fasteners.

• remove�the�fasteners�thatattach�the�bumper�cover�tothe�bumper�reinforcement.�Toavoid�damaging�plastic�retainingclips,�specialty�tools�may�berequired.�Undamaged�fastenersshould�be�labeled�and�stored�forreinstallation.

Due�to�the�extent�of�damage,�this�bumper�cover�willbe�replaced.

When�the�fasteners�have�been�removed,the�bumper�cover�can�be�removed�fromthe�vehicle.�If�repairs�are�to�be�made,the�type�of�plastic�can�be�identified�tohelp�identify�the�recommended�repairmaterials.�If�damaged�beyond�repair,�thebumper�cover�can�be�discarded.�Beforediscarding,�make�sure�that�all�parts�havebeen�removed�such�as�license�plates,clips,�etc.

This�energy�absorber�will�fit�inside�of�the�bumpercover.

With�the�bumper�cover�removed,�theenergy�absorber�will�be�visible.�Energyabsorbers�are�commonly�foam�or�plastic.Foam�energy�absorbers�are�often�madeof�polypropylene.�Some�vehicle�makershave�repair�recommendations�forminor�damage�to�these�types�of�energyabsorbers.

Because�a�bumper�cover�may�return�toits�original�shape�following�a�collision,damage�to�the�energy�absorber�maynot�be�evident�during�initial�damageanalysis.

After�removing�this�energy�absorber,�damage�to�thereinforcement�is�revealed.

To�remove�an�energy�absorber,�it�shouldbe�unbolted�or�unclipped�from�the

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 17

bumper�reinforcement.�If�the�energyabsorber�is�unrepairable,�it�should�bediscarded.

The�bumper�reinforcement�prevented�damage�to�thisair�conditioning�condenser.

With�the�energy�absorber�removed,�thebumper�reinforcement,�or�impact�bar,is�visible.�The�bumper�reinforcement�isattached�to�the�lower�rails�on�a�unibodyvehicle.�The�bumper�cover�and�energyabsorber�are�attached�to�the�bumperreinforcement.�Bumper�reinforcements�arevery�strong�and�assist�in�collision�energymanagement.�Bumper�reinforcements�maybe�made�of:

• UHSS.• reinforced�composite�material.• aluminum.

Bumper�reinforcements�are�usually�not�repairable.This�one�will�require�replacement.

There�may�be�hidden�damage�to�thebumper�reinforcement�that�is�not�visiblewith�the�bumper�cover�installed.�Mostbumper�reinforcements�are�removedby�unbolting�it�from�the�mounting�areaon�the�lower�rail.�Damaged�bumperreinforcements�should�not�be�repaired.

The�bumper�reinforcement�on�this�vehicle�is�beingreplaced.

To�install�a�bolted�bumperreinforcement:

• refinish�first�if�required.�Bumperreinforcements�that�are�visiblethrough�the�bumper�cover�orfascia�may�require�refinishing.To�determine�if�the�replacementbumper�reinforcement�should�be

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 18

refinished,�inspect�the�damagedreinforcement.

• install�the�reinforcement�inplace�and�temporarily�install�theabsorber�and�bumper�cover.

• align�the�bumper�reinforcement,�ifadjustable.

• tighten�the�fasteners�tothe�recommended�torquespecification.

Some�trim�may�need�to�be�re-attached�to�thebumper�cover.

License�plate�mounting�brackets�may�need�to�be�re-attached.

The�grille�may�need�to�be�re-attached�on�somebumper�covers.

After�installing�the�bumper�reinforcementand�energy�absorber,�the�bumper�covercan�be�installed.�Tape�may�be�used�tohold�a�foam�absorber�in�position�whilethe�bumper�cover�is�installed.�Steps�forinstalling�a�bumper�cover�include,�but�arenot�limited�to:

• refinishing�the�replacementpart.�This�should�be�done�off�ofthe�vehicle�to�ensure�completecoverage�on�areas�that�may�becovered�when�the�bumper�isinstalled.

• installing�any�moldings,�brackets,or�lamps�that�have�fasteners�thatcannot�be�accessed�followinginstallation�of�the�bumper�cover.

• installing�the�bumper�coveror�fascia�and�inspecting�thealignment.�Typically,�there�will�belimited�adjustment�available.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 19

Install�any�required�fasteners�for�bumper�coverattachment.

After�the�bumper�cover�is�installed,�verify�the�panelalignment.

Complete�the�bumper�cover�installationby:

• reconnecting�any�electricalconnectors�and�verifying�that�theyoperate�properly.

• installing�the�required�fasteners.These�will�usually�be�some�designof�plastic�push�pin,�but�may�alsoinclude�screws�or�bolts.�Torqueto�specification�whenever�aspecification�exists.

• installing�any�additional�trim�asrequired�such�as�moldings,�licenseplate�mounting�brackets,�and�stepplates.

Refer�to�“Video:�Bumper�CoverReplacement”�in�the�presentation.�Thisvideo�discusses�how�to�replace�a�plasticbumper�cover.

Steel�Bumpers

Trucks�commonly�use�a�steel�bumper�which�mayinclude�plastic�covers.

Steel�bumpers�are�most�often�found�onbody-over-frame�vehicles�such�as�trucksand�SUVs.�Some�steel�bumpers�may�alsohave�a�plastic�bumper�cover�or�air�damattached�to�it.�Some�rear�bumpers�have�atrailer�hitch�attached�to�it.�These�shouldbe�inspected�for�damage�to�the�mountingarea.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 20

This�bracket�attaches�the�steel�bumper�to�the�frame(left).�Brackets�may�be�bolted�to�the�frame�assembly(right).

Bumper�brackets�are�used�to�attach�thebumper�to�the�frame.�Adjustable�bumpersare�usually�attached�to�the�frame�withbolts�and�U-clips.�Bumper�brackets�areoften�collapsible�and�may�be�responsiblefor�collision�energy�management�and�mayaffect�airbag�timing.

Some�fasteners�may�be�hidden�behind�trim.

To�remove�a�steel�bumper:

• protect�adjacent�panels�to�preventdamage.

• disconnect�any�attached�lightingor�accessories�such�as�drivinglamps.�It�may�be�necessary�toremove�the�air�dam�for�bumperremoval.

• it�may�be�necessary�to�removesome�trim�pieces�or�otherattachments�to�gain�access�tohidden�fasteners.�If�there�areno�hidden�fasteners,�trim�maybe�removed�following�bumperremoval.

Bumper�removal�may�require�the�help�of�anassistant.

This�bracket�is�being�inspected�for�damage.

Continue�the�steel�bumper�removal�by:

• removing�the�fasteners�thatattach�the�bumper�to�the�vehicle.Depending�on�access,�determineif�the�bumper�will�be�removedfrom�the�bumper�bracket�or�if�thebumper�bracket�will�be�removed

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 21

from�the�frame.�When�removingthe�bumper�fasteners,�note�thelocation�of�mounting�hardware.This�will�be�beneficial�wheninstalling�the�replacement�bumper.

• having�an�assistant�help�removethe�bumper,�if�required.

After�removing�a�steel�bumper,�closelyinspect�the�bumper�brackets�anddetermine�if�the�brackets�and�fastenerswill�require�replacement.

An�assistant�may�be�required�when�installing�abumper.

To�install�a�steel�bumper:

• install�any�trim�that�will�notbe�accessible�after�bumperinstallation.

• protect�adjacent�panels.�Since�thebumper�will�usually�be�installedfollowing�repairs�and�refinishing,it�is�important�to�not�damagethe�fenders.�Masking�tape�orprotective�blankets�may�be�used.

• use�an�assistant�to�help�withinstallation�to�avoid�damagingthe�bumper�or�adjacent�panels,�ifrequired.

• temporarily�install�the�fastenersbased�on�the�original�location.Look�for�signs�of�where�thefasteners�were�previously�installed,such�as�missing�paint.

• verify�lamp�operation,�ifapplicable,�before�permanentlyinstalling�the�fasteners.

• adjust�the�bumper�as�required.

This�bumper�will�have�to�be�adjusted�so�that�thegaps�between�the�lamps�and�the�bumper�areconsistent�from�side-to-side.

The�gaps�will�need�to�be�adjusted�on�this�side�of�thebumper�also.

When�adjusting�a�steel�bumper:

• inspect�the�gaps�from�the�bumperto�the�fenders,�headlamps,�and

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 22

grille.�The�gaps�should�be�uniformfrom�side-to-side.

• filler�or�closeout�panels�should�beinstalled�to�ensure�proper�fit.

• it�may�be�necessary�to�adjust�abolted�radiator�core�support�forproper�bumper�alignment.

• an�assistant�may�be�helpful�forraising�and�lowering�the�bumperwhile�tightening.

After�the�bumper�is�aligned,�anyremaining�trim�can�be�reinstalled.�Torquethe�steel�bumper�to�specification�whenavailable.

On�this�body-over-frame�vehicle,�adjustments�are�inthe�form�of�slotted�holes.

Depending�on�the�bumper,�bumperbrackets,�and�frame�construction,�steelbumper�adjustments�may:

• be�limited.• include�height.• include�forward�and�rearward

movement.• include�side-to-side�movement.

Refer�to�“Video:�Steel�BumperReplacement”�in�the�presentation.�Thisvideo�discusses�how�to�replace�a�bolted-on�steel�bumper.

Grilles

Grilles�allow�airflow�into�the�engine�compartment.

The�grille�on�some�trucks�and�SUVs�is�attached�tothe�radiator�core�support.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 23

This�grille�is�attached�to�the�bumper�cover.

Grilles�allow�for�airflow�into�the�enginecompartment�and�may�be:

• a�part�of,�or�attached�to,�thebumper�cover.�Some�grilles�aremolded�into�the�bumper�cover�andsome�are�mechanically�fastened�tothe�bumper�cover.

• attached�to�the�hood.�This�typewill�have�a�frame�that�is�attachedto�the�hood.

• attached�to�the�radiator�coresupport.�This�is�common�on�sometrucks�and�SUVs�and�typicallyhave�openings�for�the�headlamps.

The�plastic�grille�on�this�vehicle�will�requirereplacement.

Most�grilles�are�made�of�plastic.�Thosethat�are�attached�to�a�hood�have�a�steelmounting�frame�around�them.�Grillescome�in�a�variety�of�designs�and�mayhave�a�mounting�area�for�emblemattachment.

The�bumper�cover�may�require�removal�to�allow�forgrille�removal.

To�remove�a�damaged�grille,�it�may�benecessary�to�first�remove�the�bumpercover�or�fascia.�Some�may�be�accessibleby�opening�the�hood�and�will�not�requirebumper�cover�removal.�Depending�on�theattachment�method,�grilles�are�removedby�unbolting,�unclipping,�or�unscrewingthe�fasteners�and�removing�the�grille.

This�grille,�which�is�attached�to�the�bumperassembly,�has�been�replaced�and�the�bumperassembly�is�being�reinstalled.

To�install�a�grille:

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 24

• verify�the�correct�replacement�partupon�delivery.

• refinish�the�grille�as�required.Although�a�grille�may�be�orderedby�color,�it�may�require�refinishingin�order�to�achieve�the�propercolor�match.

This�headlamp�mounting�panel�is�attached�to�theradiator�core�support.

Some�vehicles�have�a�headlamp�mountingpanel�that�attach�the�grille,�headlamps,and�side�lamps�to�the�radiator�coresupport.�These�are�generally�constructedof�a�composite�plastic�material.�Someheadlamp�mounting�panels�havealignment�pins�to�ensure�correct�fitbetween�the�grille�and�front�lamps�to�thefront�body�panels.

Fenders

This�vehicle�has�steel�fenders.

The�types�of�fenders�that�are�included�inthis�course�are�bolted:

• steel�fenders.• plastic�fenders.

Fenders�are�usually�flush�with�the�hoodand�door.�Some�fenders�may�have�slightpositive�flush�with�the�front�door�toreduce�wind�noise.�Positive�flushnessfrom�the�fender�to�the�door�means�that�thefender�is�positioned�slightly�outward�fromthe�vehicle�when�compared�to�the�door.Another�way�of�saying�it�is�that�the�doorhas�slight�negative�flush�with�the�fender.

This�vehicle�has�a�one-piece�fender.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 25

Although�most�fenders�are�of�one-piececonstruction,�there�are�some�two-piecefenders�available�that�have�an�inner�fenderthat�is�welded�to�the�outer�fender.�Thesewill�typically�be�found�on�trucks�andSUVs.

Fender�attachments�may�include�molding,�such�ason�this�vehicle.

There�may�be�a�number�of�different�partsattached�to�a�fender�including,�but�notlimited�to:

• a�splash�shield.�Splash�shieldsprotect�the�engine�compartmentfrom�road�contaminants�that�arepropelled�by�a�rotating�tire.�Mudflaps�are�also�often�attached�to�thefender.

• moldings,�emblems,�and�flares.• side-marker�lamps�and�reflectors.• the�radio�antenna.• underhood�mechanical

attachments�and�electricalgrounds.�Although�not�as�commonon�unibody�vehicles,�many�trucksand�SUVs�have�mechanical�partsattached�to�the�inner�fender.

• hood�cushions.�Hood�cushionsare�used�to�support�the�centersection�on�each�side�of�the�hood

and�protect�the�fender�and�hoodfinish.

This�damaged�fender�is�being�removed�from�thisvehicle.

To�remove�a�bolted�fender�from�thevehicle�structure:

• remove�the�splash�shield�fromthe�wheelhouse�area.�The�splashshield�will�require�removal�toaccess�any�hidden�fasteners.

• remove�any�other�required�partsfor�access�to�hidden�fastenersor�parts�that�will�inhibit�fenderremoval,�such�as�rocker�moldings,cladding,�underhood�mechanicalparts,�etc.

• unbolt�and�remove�the�fender.• remove�any�moldings,�emblems,

or�other�attachments�that�will�betransferred�onto�the�replacementpart.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 26

This�fender�bolt�is�being�tightened�to�therecommended�torque�specification�(left).�The�panelgaps�are�being�verified�(right).

Before�installing�a�fender�on�a�vehicle,�theinside�edge�or�jamb�should�be�refinished.Continue�installation�by:

• installing�any�attachments�thathave�fasteners�that�will�not�beaccessible�once�the�fender�isinstalled.

• temporarily�installing�the�fenderand�attachment�hardware,�usuallybolts.

• adjusting�the�fender�as�required�tothe�front�door�and�hood.

• tightening�the�fasteners�tothe�recommended�torquespecification.

• installing�any�remainingattachments.

After�refinishing,�duplicate�the�appearanceand�application�of�any�necessarycorrosion�protection�materials�that�wereoriginally�applied�to�the�backside�of�thepart.

The�U-clip�in�the�slotted�hole�of�an�upper�rail�allowssome�adjustment�in�the�fender.

Fenders�may�use�slotted�or�elongatedholes�in�the�fender�for�adjustment,�or�theymay�be�adjustable�using�U-clips�in�theupper�rail.�Fender�adjustments�include:

• forward�or�rearward.�This�allowsfor�alignment�to�the�front�door�andbumper.

• inward�or�outward�from�theengine�compartment.

• upward�using�shims.�Because�theupper�rail�cannot�be�adjusted,�thefender�can�only�be�raised�by�usingshims.

This�fender�is�being�adjusted�inward,�indicated�bythe�finish�from�under�the�bolt�head.

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Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 27

To�move�the�front�of�the�fender�inward�oroutward,�loosen�the�front�fasteners,�adjustthe�fender,�and�tighten�the�fasteners.�Tomove�the�rear�of�the�fender�inward�oroutward,�loosen�the�rear�fasteners,�adjustthe�fender,�and�tighten�the�fasteners.

This�fender�is�being�adjusted�outward,�indicated�bythe�finish�from�under�the�bolt�head.

To�move�the�fender�forward�or�rearward,loosen�the�fasteners,�adjust�the�fender,and�tighten�the�fasteners.�Determine�ifthe�hood�needs�to�be�adjusted�to�meetthe�flushness�with�the�fender.�If�the�hoodis�in�alignment�and�the�fender�needs�tobe�raised,�shims�may�be�used�to�raisethe�fender�upward.�Shims�should�notbe�used�to�compensate�for�structuralmisalignment.

This�splash�shield�is�being�reinstalled�followingfender�replacement.

When�installing�fender�attachments:

• replace�damaged�fasteners�withthe�same�type.

• two-sided�tape�or�emblemadhesive�can�be�used�to�installtrim�after�refinishing.

• verify�that�underhood�parts�andground�connections�are�installedin�the�correct�location.�It�maybe�necessary�to�remove�paintcoatings�from�ground�attachmentlocations�if�the�fender�has�beenedged.

• it�may�be�necessary�to�touch�upthe�antenna�nut�following�antennainstallation.�This�is�because�manyantenna�nuts�are�painted�andthe�finish�may�become�damagedduring�removal�and�installation.

Activity:�Fender�Adjustment

Refer�to�Module�1,�"Activity:�FenderAdjustment"�in�the�presentation.�Thisactivity�presents�one�example�of�adjustingfenders.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 28

Hoods

Some�hoods�have�safety�catches�on�the�hinges�toprevent�intrusion�into�the�windshield�during�a�frontcollision.

Hoods�have�safety�features�built�in�such�ascollapse�zones�and�safety�stops.�Collapsezones�and�safety�stops�minimize�thepotential�for�the�hood�to�intrude�intothe�passenger�compartment�during�afront�collision.�Hoods�are�equippedwith�hinges,�latches,�and�props�andusually�have�multiple�vehicle�informationlabels.

Most�hoods�have�rear-mounted�hinges.

Although�some�hoods�have�front-mountedhinges,�where�the�hood�opens�from�theback,�most�have�rear-mounted�hinges.Hoods�may�be�made�of:

• steel.

• a�composite�material�such�assheet-molded�compound�(SMC).

• aluminum.

This�hood�has�several�parts�that�will�have�to�beremoved�and�reinstalled�on�a�replacement�hood.

Common�hood�attachments�include,�butare�not�limited�to:

• emblems.�These�are�usuallylocated�in�the�front�or�middle�ofthe�hood.

• hinges.�There�are�a�number�ofdifferent�styles�of�hinges.

• prop�rods.�Prop�rods�are�used�tokeep�the�hood�open.

• latches.�The�latch�secures�thehood�to�the�vehicle�structure.

• lighting.�When�the�hoodis�open,�underhood�lampslight�to�illuminate�the�enginecompartment.

• a�hood�insulation�pad.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 29

A�windshield�washer�nozzle�is�attached�to�this�hood.

Other�hood�attachments�include:

• grilles.• windshield�washer�spray�nozzles.• hood�scoops�and�hood�scoop

screens.• adjustable�stops.�Adjustable�stops

are�used�to�align�the�hood�heightto�the�fenders.

• aftermarket�parts�such�as�bugshields�and�cowl�covers.

This�hood�insulation�blanket�is�fastened�to�the�hoodwith�plastic�retainers.

Some�considerations�for�transferring�hoodattachments�include�determining�whento�transfer�the�parts.�Should�the�parts�beinstalled�before�hood�installation�or�after?

This�may�depend�on�personal�preferenceand�access.�If�the�hood�is�large,�such�as�atruck�hood,�it�may�be�difficult�to�transfersome�parts�after�the�hood�is�installed.Other�considerations�include:

• removal�and�installation�of�thehood�insulation�pad.�The�fastenersthat�attach�the�hood�insulation�padmay�be�difficult�to�remove�withoutdamage.�Extra�fasteners�should�beavailable.

• ordering�and�installingreplacement�identification�labels.It�will�not�be�possible�to�transferthe�labels�from�the�damaged�hoodto�the�replacement�hood.�Timelyand�accurate�ordering�of�the�labelswill�reduce�the�chance�of�thecustomer�having�to�return�at�alater�date.

• routing�of�the�wiring�harness.Note�the�routing�of�the�underhoodlamp�and�the�location�of�any�wireharness�routing�clips�and�fasteners.

This�hinge�is�mounted�on�the�firewall�of�the�vehicleand�will�require�removal�of�the�cowl�vent�panel�foraccess.

Hood�hinges�may�be�mounted:

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Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 30

• at�the�rear�of�the�hood�on�theupper�rail,�cowl,�or�fender.

• at�the�front�of�the�hood�on�theradiator�core�support.�Front-mounted�hinges�are�not�ascommon�as�rear-mounted�hinges.

• vertically�on�the�hood�undersideor�the�hood�flange.

This�hinge�uses�a�coil�spring�to�keep�the�hood�open.

There�are�a�variety�of�different�hinges,�butmost�are�constructed�one�of�three�ways.Hood�hinges�may�have:

• a�single�pin�at�the�hinging�point.• multiple,�usually�two,�pins�at�the

hinging�point.• a�coiled�spring�as�one�pivot�point.

Excluding�the�spring,�there�may�beup�to�three�additional�pivot�points.

A�conventional�prop�rod�is�attached�to�the�front�ofthis�vehicle.

Hood�props�hold�the�hood�in�the�openposition.�Ways�to�prop�the�hood�openinclude:

• using�a�piston.�Piston-type�propsrequire�no�manual�operation.They�extend�automatically�oncethe�hood�is�released�from�thesecondary�latch.

• tension�on�a�coiled�spring�hoodhinge.

• a�conventional�hood�prop�locatedon�the�radiator�core�support,upper�rail,�or�apron.�This�typerequires�unhooking�and�swingingthe�hood�prop�into�positionand�inserting�it�into�the�hoodunderside.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 31

Piston-type�prop�rods�may�use�a�ball�stud�and�asocket�with�a�retainer�clip�to�attach�them�to�thehood.

To�replace�a�piston-type�prop�rod:

• slightly�pry�the�retainingspring�clip�outward.�Try�not�tocompletely�remove�the�spring�clip.

• apply�upward�pressure�on�thehood�to�relieve�pressure�from�theprop�rod.

• remove�the�rod�from�the�ball�studfrom�either�the�hood�or�the�fender.

To�install�a�piston-type�prop�rod,�reversethe�removal�procedure.

This�hood�latching�system�has�a�striker�(top)�and�aprimary�and�secondary�latch�(bottom).

The�hood�latching�system�is�responsiblefor�keeping�the�hood�closed.�On�mostvehicles,�the�hood�latch�area�is�locatedin�the�middle�of�the�hood�on�the�radiatorcore�support.�A�typical�hood�latch�areaconsists�of:

• a�striker.�The�striker�is�usuallylocated�on�the�hood�and�issecured�by�the�hood�latch.

• the�primary�latch�and�a�releasecable.�The�primary�latch�isresponsible�for�holding�the�hoodin�the�closed�position.�The�releasecable�is�routed�from�the�radiatorcore�support�into�the�passengercompartment.�When�the�cable�ispulled,�the�primary�latch�releases.

• a�secondary�latch.�In�the�eventof�a�primary�latch�failure,�thesecondary�latch�retains�the�hoodand�prevents�it�from�opening.

There�are�other�types�of�hood�latchsystems�including�a:

• spring�striker�and�latch�assembly.• dual�latch�and�striker�system.�With

this�system,�there�are�two�strikersand�two�latches�located�to�the�leftand�right�of�the�hood�center.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 32

Shoulder�bolts�attach�this�latch�to�the�radiator�coresupport.

To�remove�a�hood�latch:

• mark�the�location�of�the�latch�forinstallation.

• remove�the�fasteners,�usuallyshoulder�bolts�that�are�threadedinto�the�radiator�core�support.

• remove�the�release�cable�andsecure�it�to�the�radiator�coresupport.�If�the�cable�is�beingreplaced,�make�note�of�therouting.

This�cable�is�used�to�pull�the�release�lever�on�thislatch.

To�replace�a�worn�or�damaged�releasecable:

• remove�the�release�cable�fromthe�latch�mechanism.�It�may�benecessary�to�remove�the�latch�toremove�the�release�cable.

• note�the�routing�of�the�cable�andremove�the�cable�from�the�enginecompartment.

• remove�the�release�mechanismfrom�the�vehicle�interior.�This�willusually�be�located�beneath�theinstrument�panel�and�fastenedwith�shoulder�bolts�or�screws.

To�install�a�hood�release�cable,�reverse�theremoval�procedure.

This�hood�latch�is�installed�on�the�radiator�coresupport.

To�install�a�hood�latch:

• install�the�release�cable�into�thelatch.

• position�the�latch�according�tothe�marks�on�the�radiator�coresupport.

• temporarily�install�the�fasteners.• align�the�latch�and�torque�the

fasteners�following�the�vehiclemaker's�recommendation.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 33

Most�hoods�will�require�help�from�an�assistant�forremoval.

To�remove�a�hood:

• an�assistant�will�be�required.• begin�by�removing�the�prop�rod,�if

it�is�a�piston-type�prop�rod.• determine�which�fasteners�will�be

removed.�Depending�on�accessand�damage,�either�the�hoodfasteners�or�the�fender�or�upperrail�fasteners�can�be�removed.

After�removing�the�fasteners,�the�hoodcan�be�removed�and�stored.�Damagedhoods�can�be�discarded�after�all�repairsare�complete.

This�hood�is�installed�with�the�attachments�alreadyinstalled.

To�install�a�replacement�hood:

• have�an�assistant�help�positionthe�hood�in�place.�Depending�onthe�removal�procedure,�this�mayinclude�positioning�the�hood�onthe�hinges�or�the�hinges�on�thefender�or�upper�rail.

• temporarily�install�the�requiredfasteners.

• align�the�hood�and�tighten�thefasteners.�Note�that�additionaladjustment�may�be�required.

• transfer�any�undamaged�hoodattachments�to�the�replacementhood�and�install�all�requiredreplacement�labels.

Hoods�can�be�adjusted�on�the�hinges�or�the�hoodstops.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 34

This�hood�stop�is�adjusted�fully�down.

This�hood�stop�is�adjusted�partially�up.

Depending�on�the�design�of�the�hood,alignment�may�be�done�by�adjustingthe:

• hood�hinges.• adjustable�stops.• striker�and�latch�area.

To�properly�align�a�hood,�it�may�benecessary�to�make�adjustments�to�anycombination�of�these.

There�is�a�special�tool�available�that�canbe�used�to�release�the�primary�hood�latch.This�eliminates�the�need�for�the�technicianto�pull�the�hood�release�mechanism

in�the�passenger�compartment�duringalignment.

When�aligning�hoods,�verify�that�there�areadequate�gaps�before�closing�to�preventdamage�to�adjacent�panels.

Most�hoods�can�be�adjusted�forward�or�backwardon�both�sides,�from�side-to-side,�and�for�flushnesswith�the�fenders.

Depending�on�the�mounting�position�ofthe�hinges,�it�may�be�possible�to�adjust�thehood:

• frontward�or�rearward.�This�isa�gap�adjustment�between�thecowl�and�bumper�assembly.�Thisadjustment�is�common�on�mosthoods.

• towards�the�driver�or�passengerside.�This�is�a�gap�adjustment�andis�common�on�most�hoods.

• for�flushness�either�up�or�down.This�can�only�be�to�the�rear�of�thehood�on�those�with�hinges�that�aremounted�vertically.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 35

Adjusting�the�stops�will�change�the�flushness�at�thefront�of�the�hood.

Adjustable�stops:

• are�used�to�raise�and�lower�thefront�portion�of�the�hood�in�orderto�accomplish�zero�flushness�withthe�fenders.

• may�be�mounted�on�the�hood.• may�be�mounted�on�the�fender�or

structure,�either�the�upper�rail�orradiator�core�support.

This�latch�can�be�adjusted�up�and�down�and�to�theleft�and�right.

The�hood�and�fender�gaps�should�beadjusted�with�the�latch�removed.�Whenthe�proper�gaps�are�obtained,�the�latchcan�be�installed�so�that�the�striker�and

latch�operate�smoothly�and�the�hood�isnot�"pulled"�to�either�side.�The�latch�maybe�adjusted�in�combination�with�the�hoodbumpers�to�align�the�flushness�with�thefenders.�Installing�the�latch�to�"pull"�thehood�to�obtain�proper�fender-to-hoodgaps�may�result�in�the�hood�and�strikerbinding�and�could�cause�the�latch�to�beinoperative.

Refer�to�“Video:�Bolted�HoodReplacement”�in�the�presentation.�Thisvideo�shows�a�bolted-on�hood�beingremoved�and�reinstalled.

Activity:�Hood�Adjustment

Refer�to�Module�1,�"Activity:�HoodAdjustment"�in�the�presentation.�Thisactivity�presents�one�example�of�adjustinghoods.

Module�1�-�Front�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 36

Module�Wrap-Up

Topics�discussed�in�this�moduleincluded:

• bumper�system�identification.• steel�bumper�replacement.• plastic�bumper�cover�/�fascia

replacement.• energy�absorber�replacement.• bumper�reinforcement

replacement.• grille�replacement.• steel�fender�replacement.• fender�alignment.• hood�replacement.• hood�alignment.

Module�2�-�RearBody�Panels

This�page�is�intentionally�left�blank.

Module�2�-�Rear�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 39

Truck�Box

Learning�objectives�for�this�moduleinclude:

• replacing�truck�boxes.• replacing�deck�lids.• replacing�liftgates�and�hatchbacks.• replacing�tailgates.

This�truck�box�is�constructed�of�steel.

Types�of�materials�used�for�truck�boxesinclude:

• steel.• composite.• steel�with�composite�box�sides.

The�fuel�filler�neck�is�being�disconnected�for�boxremoval�on�this�truck.

Use�a�cart�or�dolly�to�aid�in�moving�the�truck�box.

Steps�included�in�truck�box�removal�mayinclude,�but�are�not�limited�to:

• removing�the�fuel�filler�neck�fromthe�fuel�door�opening.�Be�sure�todisconnect�the�wire�that�providesa�ground�for�the�filler�neck�to�theframe.

• raising�the�truck�to�accessfasteners,�if�required.

• removing�the�trailer�hitch,�ifequipped.�Access�to�the�fastenersmay�require�the�hitch�to�beremoved.

• removing�the�fasteners�that�attachthe�box�to�the�frame.

• lowering�the�vehicle.

Module�2�-�Rear�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 40

• determining�how�to�lift�the�box.There�are�box�lifters�available�thatcan�be�used�with�an�engine�hoist.Assistants�can�be�used,�or�a�two-post�lift�with�planks�and�chains.

• removing�the�box�and�placing�iton�a�cart�or�dolly.

This�tail�lamp�is�being�transferred�to�the�reinstalledtruck�box.

To�install�a�truck�box:

• position�the�box�over�the�frame.• lower�the�box�onto�the�frame.• install�and�torque�the�mounting

fasteners.• transfer�any�accessories�including

the�tail�lamps�and�any�aftermarketaccessories.

This�truck�has�a�plastic�bedliner.

Some�common�aftermarket�attachmentsthat�may�require�transfer�or�installationinclude:

• tonneau�covers.�These�may�eitherbe�constructed�of�vinyl�or�acomposite�material.�Compositetonneau�covers�may�offer�somerepairability�if�damaged.

• truck�caps.�Fiberglass�or�SMCtruck�caps�may�offer�somerepairability�if�damaged.

• bedliners.�Bedliners�may�be�spray-on�or�plastic.�Damaged�boxesthat�have�a�spray-on�bedliner�mayrequire�the�bedliner�replacementto�be�sublet.

Module�2�-�Rear�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 41

Deck�Lid

This�deck�lid�has�hinges�mounted�in�the�package�trayarea.

Deck�lids�are�the�rear�closure�panels�thatcover�the�trunk�area.�Deck�lids:

• most�often�open�from�the�rear.This�means�that�the�hinges�aremounted�in�front�of�the�deck�lid,either�on�top�of�the�quarter�panelor�under�the�rear�package�tray.

• may�be�dual�opening.�Someautomatic�convertibles�open�thedeck�lid�from�the�front�to�lowerthe�convertible�top�and�can�beopened�from�the�rear�for�access�tothe�trunk.

• may�be�made�of�steel.• may�be�made�of�a�composite

material.

Deck�lid�hinges�are�designed�to�hold�a�deck�lid�inthe�open�postion.

The�deck�lid�hinges�are�responsible�for�theswinging�open�effect�of�the�deck�lid,�andkeep�the�deck�lid�in�the�open�position.Different�types�of�deck�lid�hinges�includea:

• spring�type.• piston�type.�These�are�similar�to

hood�piston�prop�rods.�These�mayalso�have�a�hinge�attached�to�theprop�rod.

• torsion�bar�type.�The�torsionbars�are�mounted�under�therear�package�tray�and�may�haveadjustments�to�accommodate�forwear.�The�torsion�bars�attach�thehinges�and�the�hinges�are�attachedto�the�deck�lid.

Module�2�-�Rear�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 42

This�deck�lid�has�several�attachments.

Attachments�that�may�require�removalor�transfer�when�replacing�a�deck�lidinclude:

• vehicle�lighting�and�associatedwiring.�Some�tail�lamps�are�part�ofthe�deck�lid.

• emblems.�These�are�found�on�mostdeck�lids�and�are�typically�thevehicle�model�emblem.

• a�rear�spoiler.�If�a�spoiler�is�anaftermarket�attachment�that�isbeing�transferred,�holes�may�haveto�be�drilled�into�the�replacementdeck�lid.�Any�holes�should�bedrilled�before�refinishing.

• information�labels.• emergency�release�levers.• the�lock�cylinder.• the�latch.�The�latch�is�installed�on

most�deck�lids,�but�some�deck�lidsmay�have�the�striker�installed.�Thestriker�and�latch�assemblies�aresimilar�to�the�type�used�on�hoodsand�some�doors.

This�hinge�has�elongated�holes�for�adjustments.

To�remove�a�deck�lid�for�replacement:

• open�and�support�the�deck�lid.• disconnect�and�label�any�wiring

that�is�attached�to�the�deck�lid.• disconnect�and�remove�the�latch.• unfasten�and�remove�the�deck�lid.

This�deck�lid�latch�is�being�reinstalled.

Module�2�-�Rear�Body�PanelsTextbook

Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 43

This�deck�lid�latch�striker�is�being�adjusted.

To�install�a�deck�lid:

• support�the�deck�lid�andtemporarily�install�the�mountingfasteners.

• check�the�alignment�and�correctas�necessary.

• torque�the�fasteners�and�recheckthe�alignment.�If�the�latch�wasremoved,�install�so�that�the�strikeris�centered�in�the�latch.�This�willprevent�the�latch�from�pulling�thedeck�lid�to�either�side.�Flushnesswith�the�quarter�panels�may�beadjusted�by�moving�the�latcheither�up�or�down.

The�deck�lid�attachments�are�being�reinstalled.

The�electrical�connections�are�being�reattached�onthis�deck�lid.

Complete�the�deck�lid�installation�by:

• installing�the�lock�cylinder�andverifying�its�proper�operation.

• transferring�any�undamagedemblems�and�reattaching�the�decklid�accessories.

Adjustments�on�this�deck�lid�include�forward�andrearward,�up�and�down,�and�from�side-to-side.

Depending�on�the�mounting�position�ofthe�deck�lid�on�the�hinges,�adjustmentsmay�include:

• up�and�down.�This�may�be�doneby�moving�either�the�deck�lid

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up�or�down�on�the�hinge�or�bymoving�the�latch�mechanism�upor�down.�If�the�front�of�the�decklid�has�to�be�raised�or�lowered,adjust�the�hinge�area.�If�the�rearof�the�deck�lid�has�to�be�raisedor�lowered,�adjust�the�latchmechanism.

• forward�or�rearward.�To�movethe�entire�deck�lid�forward,�thedeck�lid�has�to�be�moved�forwardon�the�hinges�in�the�horizontalposition.�The�opposite�appliesto�move�the�deck�lid�rearward.To�move�one�side�forward�andone�side�rearward,�slide�theappropriate�side�forward�orrearward.

• side-to-side.�Depending�on�themounting�position�of�the�deck�lidon�the�hinge,�adjustments�maybe�available�to�move�the�deck�lidfrom�side-to-side.�The�latch�shouldalso�be�moved�so�that�the�strikerand�latch�are�in�alignment.

Liftgates�And�Hatches

On�this�vehicle,�the�glass�will�open�independentlyfrom�the�liftgate,�or�the�liftgate�and�glass�will�open�asan�assembly.

Liftgates�and�hatches�are�of�similarconstruction.�Liftgates�and�hatches�may:

• have�stationary�glass�contained�inthe�hatch.�Stationary�glass�foundin�liftgates�and�hatches�usuallycontain�defrost�grids.

• have�movable�glass.�Movable�glassmay�either�lift�up�alone�or�lift�upwith�the�liftgate.

• be�made�of�steel.• be�made�of�a�composite�material.• be�made�of�aluminum.

Shown�are�the�liftgate�striker�(left)�and�hinge�(right).

Liftgates�and�hatches�are�equipped�with:

• hinges,�latches,�and�strikers�thatare�similar�to�doors.

• prop�rods�to�hold�the�liftgate�orhatch�open.�Most�of�these�aresimilar�to�the�piston-type�hoodprops.

• rear�wipers�on�many�vehicles.Some�may�also�have�washer�fluidspray�nozzles.

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Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 45

The�electrical�connections�on�a�liftgate�should�beinspected�during�liftgate�replacement.

Liftgate�and�hatch�wiring�that�requiredisconnection�before�liftgate�or�hatchremoval�may�include:

• the�rear�wiper�wiring.• heated�glass�wiring.• tail�lamp�wiring�when�the�tail

lamp�is�located�on�the�liftgate�orhatch.

• the�license�plate�lighting�wiring.• automatic�latch�release�wiring.

An�assistant�may�be�required�to�remove�a�liftgate.

Steps�included�in�liftgate�or�hatch�removalinclude,�but�are�not�limited�to:

• protecting�or�removing�and�storingthe�glass,�as�required.

• raising�and�supporting�the�liftgateor�hatch.

• disconnecting�and�labeling�thewiring�after�removing�the�trimpanel.

• using�an�assistant�to�help�in�theremoval�procedure.

• removing�the�prop�rods,�which�issimilar�to�the�procedure�used�forpiston-type�hood�props.

These�hinge-to-liftgate�fasteners�are�removed�with�asocket�and�ratchet.

Complete�the�liftgate�or�hatch�removal�byremoving�the�retaining�fasteners.�Store�theliftgate�or�hatch�if�it�will�be�reused.

This�piston-type�prop�is�installed�on�the�ball�stud.

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Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 46

To�install�a�liftgate�or�hatch:

• support�the�part�with�the�help�ofan�assistant.

• temporarily�install�the�fasteners.• align�and�correct�as�required.

Depending�on�the�mountingposition�of�the�liftgate,�adjustmentsmay�be�made�for�up�and�down,side-to-side,�and�flushness.

• torque�the�fasteners�to�therecommended�specification.

• install�the�prop�rods.�The�proprods�can�be�installed�earlier�toassist�in�supporting�the�liftgate�orhatch�if�preferred.

After�the�liftgate�has�the�correct�gaps,�the�striker�isinstalled.

Complete�the�liftgate�or�hatch�installationby:

• installing�the�striker�or�latch,�ifremoved.

• installing�the�glass,�if�required.• transferring�undamaged

accessories�or�installingreplacement�accessories�and

rerouting�and�connecting�thewiring.

• verifying�the�proper�operation�ofaccessories.

• rechecking�the�alignment�andcorrecting�as�required.

Tailgates

Most�truck�tailgates�fold�down�to�allow�access�to�thebox.

This�tailgate�is�hinged�at�the�bottom�and�the�hingesare�attached�to�the�box�structure.

Tailgates�are�most�common�on�pickuptrucks.�Tailgates�on�trucks�fold�down�togain�entry�to�the�truck�box.�Some�SUVsare�equipped�with�a�tailgate�and�maycontain�movable�glass.�Tailgates�may�bemade�of�steel,�a�composite�material,�oraluminum.

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The�strikers�are�mounted�to�the�inner�box�structure.The�latch�assemblies�are�installed�in�the�tailgateshell.

Tailgate�operation�accessories�mayinclude�the:

• handle�and�the�linkage.• latching�mechanisms.�Most

tailgates�have�dual�latches�oneither�side�of�the�tailgate.�Thelatches�are�connected�to�thehandle�by�linkages.

• hinging�mechanism.�Sometailgates�have�cups�that�makea�pivot�point�that�the�tailgatehinges�on.�Other�tailgates�usewelded�hinges�that�have�pins�andbushings�that�the�tailgate�pivotson.�Adjustments�on�a�tailgate�arelimited�to�aligning�the�flushnessby�moving�the�strikers�either�in�orout.

• cables�to�prevent�the�tailgate�fromopening�too�far.

• torsion�springs.�Torsion�springsare�used�mainly�on�SUV�tailgatesdue�to�the�added�weight�ofaccessories.�The�torsion�springaids�in�the�opening�and�closingeffort.�Support�straps�or�cablesprevent�the�gate�from�opening�toofar.

This�retainer�strap�has�a�metal�retainer�clip�toprevent�it�from�falling�off�of�the�stud.

When�installing�a�tailgate,�reverse�the�removalprocess.

To�replace�a�tailgate:

• lower�the�tailgate�to�access�thestraps�and�hinging�mechanism.

• slightly�lift�upward�on�the�tailgateand�remove�the�retainer�straps.

• lift�the�slotted�side�of�the�tailgateand�slide�the�tailgate�off�of�thevehicle�or�remove�the�hinges�byunbolting.

To�install�a�tailgate,�reverse�the�removalprocedure.

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Bolted-On�Exterior�Panels�-�Part�2�(EXT04e) 48

Module�Wrap-Up

Topics�discussed�in�this�moduleincluded:

• truck�box�replacement.• deck�lid�replacement.• liftgate�and�hatchback

replacement.• tailgate�replacement.