Rear Bumper: Service and Repair

Rear Bumper Mounting

Removal





1.
NOTE:
The rear bumper mounting is manufactured from mild steel.

The rear bumper mounting is serviced on the back panel and must be removed from this to carry out this procedure.

2. The rear bumper mounting is replaced in conjunction with:
- Rear bumper cover
- Rear bumper

3. For additional information relating to this repair procedure please see the following: For additional information, refer to Health and Safety Precautions
For additional information, refer to Body Repairs
For additional information, refer to Corrosion Protection
For additional information, refer to Body and Frame

4. Disconnect the battery ground cable. For additional information, refer to Battery Disconnect and Connect

5. If the right-hand rear bumper mounting is to be repaired, remove the battery. For additional information, refer to Battery

6. If the right-hand rear bumper mounting is to be repaired, remove the battery tray.

7. Disconnect the generator electrical connectors.

8. Remove the rear bumper. For additional information, refer to Rear Bumper

9. Remove any electrical components in the local area of repair to prevent damage.

10. If the right-hand rear bumper mounting is to be repaired, remove the auxiliary junction box (AJB). For additional information, refer to Auxiliary Junction Box (AJB)

11. Release the external back panel wiring harness and pull through into the loadspace.

12. Remove the luggage compartment lid weatherstrip.





13. Remove the spare wheel and tire (if equipped).





14. Remove the subwoofer speaker (if equipped).

15. Release and position the back panel and loadspace wiring harness to one side.

16. Remove the right-hand or left-hand muffler and tailpipe as necessary. For additional information, refer to Muffler and Tailpipe

17. Remove the right-hand or left-hand muffler and tailpipe heatshield as necessary.





18. Drill out the spot welds.

19. Separate the joints and remove the old panel.

Installation





1.
NOTE:
Spot welds must be drilled from the inside, this will enable the new panel to be spot welded on installation.

Drill the rear bumper mounting off the back panel service panel.

2. Prepare the old and new panel joint surfaces.

3. Offer up the new panel and clamp into position. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.





4.
NOTE:
Spot welds must be installed 5mm away from the originals and in the same quantities, whenever this is possible. Where this is not possible, spot welds should be installed adjacent to the original. Where there is adhesive in the original joint, spot welds should be installed through the original.

Spot weld.

5. Dress all welded joints.

6. The installation of associated panels and components is the reversal of removal procedure.