service LAND ROVER FRELANDER 2 2006 Manual PDF

7. Saw cut the old panel at the point illustrated.
8. Separate the joints and remove the old panel.
Installation
1. NO TE: Ens ure t he re i s a 50mm mi ni mum s t a gge r be t we e n
the old side member and the new reinforcement section cuts.
Remove a section of reinforcement from the old panel:
1. Saw cut the reinforcement at the point illustrated,
do not cut through the side member.
2. Mil l out 5 s pot welds .
3. Se p a ra t e a nd re mo ve t he re i nf o rce me nt re mna nt .
2. NO TE: Ens ure t he re i s a 50mm mi ni mum s t a gge r be t we e n
the old side member and the new reinforcement section
cut s .
Remove the rear side member section from the service
panel:
1. Sa w cut t he s i de me mbe r a t t he poi nt
illustrated, do not cut through the
re i nf o rce me nt .
2. Mil l out 5 s pot welds .
3. Saw cut the reinforcement at the point
illustrated.
4. Se pa ra t e a nd re move t he s i de me mbe r s e ct i on.
3. Prepare the old and new panel joint surfaces.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Side Member Closing Panel
Removal and Installation
Removal
• NOTE: The rear side member closing panel is serviced as a separate weld-on panel.
• NOTE: The panel is serviced less its weld studs.
• NOTE: It is necessary to remove the spare wheel well to allow access to the rear side member closing panel.
1. The rear side member closing panel is replaced in conjunction
with:
Rear bumper cover
Re a r bumpe r a rma t ure
Back panel
Re a r bumpe r mo unt i ng
Inner back panel assembly
Re a r s i de me mbe r s e ct i o n
Spare wheel well
Fuel t ank
Rear subframe and suspension assembly
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re move t he re a r s i de me mbe r s e ct i on.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : R e a r Si d e Me mb e r Se ct i o n
(501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
4. Remove the rear subframe / suspension as an assembly.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Subframe
(502-00
Uni-Body, Subframe and Mounting System, Removal and
Installation).
5. Remove the fuel tank.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Fuel Tank
(310-01A Fuel
Tank and Lines - I6 3.2L Petrol, Removal and Installation).
6. Mill out the spot welds.
7. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Spare Wheel Well
Removal and Installation
Removal
• NOTE: The spare wheel well is serviced as a separate weld on panel, it includes the spare wheel retaining bracket but
not the crossmember.
• NOTE: The panel is serviced less its weld studs
1. The spare wheel well is replaced in conjunction with:
Rear bumper cover
Rear bumper
Back panel
Back panel assembly
Fuel t ank
Rear subframe and suspension assembly
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Remove the back panel assembly.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Back Panel
(501-30 Rear
End Sheet Metal Repairs, Removal and Installation).
4. Remove the rear subframe and suspension as an assembly.
5. Remove the fuel tank.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Fuel Tank
(310-01A Fuel
Tank and Lines - I6 3.2L Petrol, Removal and Installation) /
Fuel Tank
(310-01B Fuel Tank and Li nes - TD4 2.2L Di es el,
Removal and Installation).
6. Remove the rear seat.
7. Remove the RH and LH rocker panel inner trims.
8. Remove the RH and LH rear quarter panel mouldings.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Quarter Panel
Moulding (501-08 Ext eri or Trim and Ornament at i on, Removal
and Installation).
9. Release and lay aside the carpet.
10. Remove the RH and LH brake pipes.
11. Release and lay aside the wiring harnesses at the floor panel
and inner quarter panels.
12. Mill out the spot welds.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Wheelhouse Outer
Removal and Installation
Removal
• NOTE: The rear wheelhouse outer is serviced as a separate weld-on panel.
1. The rear wheelhouse outer is replaced in conjunction with:
Rear bumper cover
Quarter panel
Rear door
Quarter glass
I nne r q ua rt e r p a ne l
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re mo ve t he i nne r q ua rt e r p a ne l .
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Inner Quart er Panel
(501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Back Panel
Removal and Installation
Removal
• NOTE: The back panel is serviced as a separate weld-on panel, it includes the bumper retaining bracket.
• NOTE: It is necessary to remove sections of both rear lamp mounting panels to enable removal and refitment of the back
panel , (unl es s t he back panel i s being replaced i n conjunct i on wit h a rear l amp mount ing panel ).
1. The back panel is replaced in conjunction with:
Rear bumper cover
Rear bumper
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re move t he re a r bumpe r.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Bumper
(501-19
Bumpe rs , Re mo va l a nd Ins t a l l a t i on).
4. Remove the RH and LH bumper retainer guides.
5. Remove the liftgate aperture weatherseal.
6. Remove the back panel trim.
7. Remove t he RH and LH quart er panel i nner t ri ms .
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Quarter Trim Panel
(501-05 Int eri or Trim and Ornament at i on, Removal and
Installation).
8. Remove the RH and LH forced air extraction grilles.
9. Remove the spare road wheel.
10. Remove the subwoofer amplifier.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Subwoofer Amplifier
(415-01 Information and Entertainment System, Removal and
Installation).
11. Re move t he e xha us t a s s e mbl y.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Exhaust Syst em
(309-00A
Exhaus t Sys t em - I6 3.2L Pet rol , Removal and Ins t all at ion).
12. Remove the floor panel exhaust heat shield.
13. Remove the RH and LH road wheels.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Wheel and Tire
(204-04
Wheels and Tires, Removal and Installation).
14. Release and lay aside the insulating material at the back
panel.
15. Release and lay aside the back panel wiring harness.
16. Saw cut each rear lamp mounting panel, as illustrated.17. Mill out the spot welds.18. Separate the joints and remove the rear lamp mounting
panel sections, retain the sections for refitment.19. Mill out the spot welds.
20. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces, including the
rear l amp mount i ng panel s ect ions .

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Crossmember
Removal and Installation
Removal
• N O T E: T he re a r cro s s me mb e r i s s e rvi ce d a s a s e p a ra t e we l d -o n p a ne l .
• NOTE: The panel is serviced less its weld studs.
1. T he re a r cro s s me mb e r i s re p l a ce d i n co nj unct i o n wi t h:
Rear bumper cover
Re a r bumpe r a rma t ure
Back panel
Inner back panel assembly
Spare wheel well
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Remove the spare wheel well.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Spare Wheel W ell
(501-30
Rear End Sheet Metal Repairs, Removal and Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
2. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
3. Sp o t w e l d .

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Side Member Lower Side Extension
Removal and Installation
Removal
• NOTE: The rear side member lower side extension is serviced as a separate weld-on panel, it is also serviced as part of
t he re a r s i de me mbe r.
1. The rear side member lower side extension is replaced in
conjunct ion wit h:
Rear bumper cover
Re a r bumpe r a rma t ure
Rear l amp mount ing panel
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re move t he re a r l a mp mount i ng pa ne l .
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Lamp Mount i ng Panel
(501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation
1. Prepare the old and new panel joint surfaces.
2. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.
3. MIG pl ug we l d.
4. Dress all welded joints.
5. The installation of associated panels and mechanical
components is the reverse of removal.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Lamp Mounting Panel
Removal and Installation
Removal
• NOTE: The rear lamp mounting panel is serviced as a separate weld-on panel.
• NOTE: There are NVH elements attached to the old panel, they are not serviced on the new panel. If damaged, new
elements will be required.
1. The rear lamp mounting panel is replaced in conjunction with:
Rear bumper cover
Re a r bumpe r a rma t ure
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re move t he re a r bumpe r.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Bumper
(501-19
Bumpe rs , Re mo va l a nd Ins t a l l a t i on).
4. Disconnect both battery cables.
5. Remove the D-Pillar trim panel.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : D-Pillar Trim Panel
(501-05
Int erior Trim and Ornamentat ion, Removal and Installat ion).
6. Re mo ve t he re a r w he e l a nd t i re .
7. Remove t he rear quart er window moulding.
8. Remove the loadspace trim panel.
9. Remove the forced air extraction grille.
10. Release the insulating material and lay aside.
11. Release and lay aside the wiring harness.
12. Use a belt sander to sand down the spot welds in the area
illustrated.

Publ is hed: 11-May-2011
Rear End Sheet Metal Repairs - Rear Wheelhouse Front Extension
Removal and Installation
Removal
• NOTE: The rear wheelhouse front extension is to be unpicked from the rear wheelhouse outer service panel.
1. The rear wheelhouse front extension is replaced in conjunction
with:
Rear bumper cover
Quarter panel
Rear door
Quarter glass
I nne r q ua rt e r p a ne l
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re mo ve t he i nne r q ua rt e r p a ne l .
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Inner Quart er Panel
(501-30 Rear End Sheet Metal Repairs, Removal and
Installation).
4. Mill out the spot welds.
5. Separate the joints and remove the old panel.
Installation

1. Remove the rear wheelhouse front extension from the
wheelhouse outer service panel.
2. Prepare the old and new panel joint surfaces.
3. Drill holes in the new panel ready for MIG plug welding.
4. Offer up the new panel and clamp into position. Check
al ignment , i f correct , proceed t o next s t ep, i f not , rect i fy and
recheck before proceeding.