Strut Housing: Service and Repair

Front Wheelhouse/Damper Housing

Removal

Mass production body welding positions and numbers (Wheelhouse upper member, lower member, and damper extension)







Mass production body welding positions and numbers (Damper housing)







Construction

NOTE: This information explains the procedures after removal of all related parts. For the related parts removal procedure, refer to the appropriate Service Procedures.

- Remove the wheelhouse upper member.
- Replace the wheelhouse lower member and the wheelhouse lower extension as an assembly.
- Check the gusset plate and the side frame gusset. If necessary, replace them.







Construction

NOTE: This information explains the procedures after removal of all related parts. For the related parts removal procedure, refer to the appropriate Service Procedures.

- Check the front damper extension and the damper housing position for damage. If necessary, replace them.

NOTE: When replacing the front damper extension, drill the position shown in DETAIL: X and DETAIL: Z from the outside of the dashboard upper side member, and drill the two spot welded points (A) at the joint for the front damper extension and the damper housing with a dia. 10 mm (0.4 in.) spot cutter.

- Drill the two spot welded points (B) at the damper housing and the dashboard upper from the underside of the damper housing.







Installation







1. Clamp the new damper housing, the front damper extension, the side frame gusset, the gusset plate, the wheelhouse lower extension, and the bulkhead, and measure the front compartment diagonally.
2. Check the body dimensions.
- Engine compartment
- Engine/transmission mount position
- Front wheelhouse lower member position
- Engine compartment and front floor, under view
- Repair chart, top view
- Repair chart, side view

3. Tack weld the new parts and the front bulkhead into position.
4. Temporarily install the front subframe, and check the front side frame position.
5. Temporarily install the front fender, the hood, and the door, then check for differences in level and clearance. Check the external parts fitting position. If necessary, check the headlight and the front bumper positions. Make sure the body lines flow smoothly.
6. Do the main welding.
Weld the damper housing (A) to the front side frame (B) and the dashboard upper (C).







7. From the passenger's compartment side, plug weld the holes in the dashboard lower (A) and the damper housing (B).







8. Drill the holes for welding the new front damper extension (A).Weld the damper housing (B), the front damper extension, and the dashboard upper side member (C).







9. Weld the damper housing (A) and the wheelhouse gusset (B) to the front damper extension (C).Weld the front damper extension and the wheelhouse lower extension (D).







10. Weld the side frame gusset (A) and the gusset plate (B) to the front side frame (C) and the wheelhouse lower extension (D).







11. Weld the front bulkhead.
12. Weld the wheelhouse upper member (A).When reusing the wheelhouse upper member, weld it with MIG plug welding.