For 1990-2009 cars

The side space frame openings feature a modular build subassembly design to improve manufacturing quality. There are many subassemblies that are pre-assembled and then attached to the vehicle as a single unit.

The door frame can be replaced as a complete unit, or in various sections as specified in this manual. However there are some key structural areas where sectioning should not take place.

Important: Structural reinforcements should not be cut. Sectioning joints should be buttweld in design and reinforced unless otherwise specified.

Sectioning procedures specified in this manual can be performed only in the areas specified. Only the parts specified in this manual may be sectioned.

Some points to consider are as follows:

• | Note amount and location of spot welds to be replaced.

• | Joints should be made as per procedures specified in the directions in this manual.

• | Use 8 mm (5/16 in) plug welds.

• | Remove sealer and drill spot welds from areas necessary.

• | Welds should equal amount and placement of factory welds.

• | Buttweld joints should have a gap one and one half times the metal thickness where the two pieces will be joined. The joint reinforcement behind the joint should be 100 mm (4 in) long.

| Important: Clean all of the weld seams with a wire brush, prime, and seal all of the repair areas. Apply permanent underbody sealant. It is important that proper corrosion protection processes are used on all repair areas. Prime with 2-part catalyzed primer. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.

• | Clean the surfaces for welding and grind primer off of the new part at connecting points. Apply 3M® Weld-Thru coating P/N 05913, or equivalent, to all areas to be welded.