PRE-RELEASE
Front wheel housing and front frame member
| Front wheel housing and front frame member |
| 1. |
Remove the door frame, see
Section of door frame, 3D
,
Door frame, 3D
or
Section of door frame, 5D
.
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| 2. |
Position the car in an aligning bench and cross-measure if necessary.
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| 3. |
Position a door opening support between the floor and roof so that the roof does not sag when the wheel housing is removed.
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| 4. |
Cut the wheel housing so that the welding points are accessible with a spot-welder.
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| 5. |
Drill out the spot-welds and tap loose the remaining sections of the wheel housing.
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| 6. |
Cut the crossmember according to the markings shown on the illustration.
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| 7. |
Drill out the welds that hold the frame member and the cut section of the crossmember. Drill through all panels, including the floor. Grind away the seam welds.
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| 8. |
Remove the frame member and crossmember cut sections and align any sheet metal or panel damage.
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| 9. |
Drill holes in the body where the new frame member is to be welded.
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| 10. |
Grind clean the surfaces on the to be welded on the frame member and body.
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| 11. |
Remove grinding debris from the inside of the frame member, otherwise the risk for corrosion increases.
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| 12. |
Apply welding primer on the surfaces to be plug-welded. Use Teroson Zinkspray.
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| 13. |
Fit the frame member and fixate with a couple of welding clamps. Adjust the exact position using the aligning bench measuring system.
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| 14. |
Plug and seam weld the frame member in place.
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| 15. |
Cut the crossmember to size.
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| 16. |
Fit the crossmember and fixate with a couple of welding clamps.
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| 17. |
Remove the crossmember and drill holes for plug-welding in the crossmember.
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| 18. |
Grind clean the surfaces to be welded on the crossmember and the body.
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| 19. |
Apply welding primer on the surfaces to be plug-welded. Use Teroson Zinkspray.
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| 20. |
Fit the crossmember and fixate with a couple of welding clamps.
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| 21. |
Plug-weld the crossmember.
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| 22. |
All-weld the joint on the crossmember.
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| 23. |
Drill holes for plug-welding in the new wheel housing, where it is not possible to reach with a spot-welder.
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| 24. |
Grind clean the surfaces to be welded on the body and in the new wheel housing.
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| 25. |
Apply welding primer on the surfaces to be plug and spot-welded on the wheel housing and on the body. Use Teroson Zinkspray.
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| 26. |
Fit the new wheel housing and fixate with a few welding clamps.
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| 27. |
Measure in the wheel housing using the aligning bench measuring system.
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| 28. |
Fasten the wheel housing with a couple of welds.
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| 29. |
Fit the front wing and the bonnet, check the fit of the wheel housing.
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| 30. |
Remove the front wing and bonnet.
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| 31. |
Spot and plug-weld the housing into place.
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| 32. |
Grind the welds.
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| 33. |
Grind clean the surfaces to be welded on the body and reinforcements that are to be fitted on the outside of the wheel housing.
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| 34. |
Apply welding primer on the surfaces to be spot-welded. Use Teroson Zinkspray.
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| 35. |
Weld on the reinforcement on the outside of the wheel housing.
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| 36. |
Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.
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| 37. |
Saab 9-3 Viggen:
The two lower studs in the wheel housing behind the front wheel should be cut to give clearance for the wheel. Cut them to a maximum length of 11 mm, measured from the body panel. Then use nuts, part no. 47 41 203, to fit the wing liner. Grind the nuts to a thickness of 8 mm. 
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| 38. |
Apply primer to all ground surfaces. Use Standox 1K Primer.
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| 39. |
Seal joints and sheet metal flanges with sealant. Use Terostat 1K-PUR.
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| 40. |
Apply underbody sealant to the underside of the frame and crossmember. Use Terostat 9320.
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| 41. |
Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400 or Mercasol 1.
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