|
|
Technical Service Bulletin 96-20-11 (supersedes TSBs 90-17-06 & 95-14-09A) Instruction Sheet 6661, P.2
________________________________________________________
If the wire is accidentally cut, then splice using butt splice or equivalent, and wrap with electrical tape. Check and replace fuse No. 8 if it has been blown.
14. Use a pair of pliers or vice-grips to bend the curled down portion of the left hand drip rail straight for better access to the sail panel underneath it (refer to Figure 4).
NOTE: The remainder of this repair must be performed with all four wheels in the same plane. If repair is performed with the body twisted, then the braces will be stressed when the vehicle is level.
OUTER SKIN CRACK REPAIR
15. Remove the weather strip on the aft end of the roof for the fiberglass cap. For removal refer to Service Manual. Section 46-51 (before 1991) or 01-08 (after 1990).
16. Sand localized area to bare metal.
17. Drill out the ends of the cracks with a 1/8" bit (refer to Figure 5).
18. MIG weld the crack using ER70S-6 wire.
19. Metal finish and prepare for prime coat.
PREPARING THE METAL, APPLYING THE METAL REINFORCEMENTS AND EPOXY
NOTE: To dispense epoxy, use Kent Ind. Dual Syringe Gun (Part No. 90375). If needed, order from Kent Ind., 1-800-654-6333, the cost in 1995 was $49.95.
20. Use a grinding stone. sandpaper, or wire brush on a drill to remove surface rust on the inside of the roof and sail panels and to clean the surface where the two-part epoxy will be applied (refer to Figure 6).
21. Use a grinding stone, sandpaper, or wire brush on a drill to score the periphery of the access hole for better adhesion of the two-part epoxy for the cover plate (refer to Figure 6).
22. Prepare the surfaces for the two-part epoxy by wiping them with a solvent using a clean cloth. Ensure that there is no residue left on the surfaces. All surfaces should be scored and cleaned (refer to Figure 7).
23. Score the surfaces of the metal reinforcements. Use a solvent and clean cloth to wipe the surfaces clean for better adhesion with the two-part epoxy (refer to Figure 8 ).
24. If the unit is equipped with a brace (refer to Figure 9), then pump the two-part epoxy between the brace, the outer sheet metal roof and the sail panel. Use a blunt chisel and hammer to bend the forward standing flange on the brace as close to the outboard side of the roof and sail panels as possible, without contacting the roof and sail panels (refer to Figure 9).
25. To prevent loss of reinforcement down the B-pillar, stuff it with cloth towels or block by other means. Practice inserting and removing the reinforcements to get used to handling the parts in the confined space. Determine if the reinforcement for the sail panel fits snug; if not, bend the reinforcement so that is does (refer to Figure 108 ).
26. Apply the two-part epoxy to the sail panel and the sail panel reinforcement, and place into position (refer to Figures 10A and 10B). The reinforcement should fit snug and should not require clamping. If the unit is not equipped with a brace from the factory, then ensure that the off-set is filled with two-part epoxy material.
27. Apply the two-part epoxy to the roof panel and the roof panel reinforcement, and place into position (refer to Figures 11A and 11B). The reinforcement should rest in place on top of the drip molding and should not require clamping.
|
