Front Strut / Shock Tower: Service and Repair
Replacement
1. Remove the related parts.
- Parts to be removed when removing the front bulkhead
- Parts on passenger side of lower dashboard which are especially flammable
- Electrical accessories in engine compartment and wire harnesses.
2. Pull out and straighten the damaged area to approximately the original shape.
- Attach the car to the frame straightener by tightening the underbody clamps at the horizontal pinch weld points.
- Before cutting off the damaged sections, pull them out so that they are restored to the original shape.
- Do not pull out more than necessary.
- Pull out and straighten the damaged area of the lower dashboard, front pillar, and other parts.
- After pulling, check the damper housing position using the body dimensional drawings and positioning jig.
NOTE: Check the condition of the door and hinges.
3. Peel off the undercoat.
Heat the undercoat at the weld areas of the wheelhouse and front side frame with a gas torch, and peel off the undercoat with a metal spatula.
CAUTION: Be careful not to burn the fittings inside the passenger compartment and dashboard insulator when heating.
4. When replacing the front wheelhouse.
- Center punch around the spot weld imprints on the front side frame and damper housing.
- Drill holes in the center punched areas using a spot cutter.
- Using a chisel, pry off the welded flange.
- Level and finish the burrs on the welding surfaces with a sander.
5. When replacing the damper housing and front wheelhouse as an assembly.
-1 Remove the wheelhouse upper member.
- Center punch around the spot weld imprints.
- Use the special spot cutter to drill holes at the spot weld nuggets.
- Remove the MIG weld flange with a disc sander.
WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.
- Using a chisel, pry off the welded flange from the front pillar and damper housing.
NOTE: Remove the wheelhouse upper member carefully so they can be reused.
-2 Using a spot cutter, drill holes in the spot welded area on the front side frame and dashboard upper side member.
-3 From the passenger compartment side, drill holes in the spot welded area with as mm (0.2 in).
NOTE: Drill holes completely through the parts since the replacement damper housing will be welded by MIG welding.
6. Mold the related parts.
- Level and finish the burrs left on the welding surfaces with a sander.
- Fill all drilled holes by MIG or gas welding.
- Use a hammer and dolly to even out the welded areas of the lower dashboard, front side frame and dashboard upper side member.
7. Set the new front wheelhouse and damper housing.
- Apply body paint to both sides of the new front wheelhouse and damper housing.
- See Paint Repair section.
WARNING:
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening the paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
- Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.
- Remove the undercoat from both sides of the welding section and expose the steel plate using a disc sander
WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding
- Clamp to the front side frame with vise-grips and squill vises.
NOTE:
- Apply the spot sealer to the welding surface when spot welding.
- Clamp the front bulkhead with vise-grips.
- Measure the front compartment diagonally.
NOTE: Use of a positioning jig is recommended.
- Spot weld several points in the clamped sections, and temporarily attach the front wheelhouse and damper housing
WARNING: To prevent eye injury and bums when welding, wear an approved welding helmet, gloves and safety shoes.
8. Check the dimensions, temporarily install the hood, front fender and headlight, and check for differences in level and clearance.
- Check the engine and transmission mount brackets position.
9. Perform the main welding.
- Weld as much as possible with the jig still mounted.
WARNING: To prevent eye injury and bums when welding, wear an approved welding helmet, gloves and safety shoes.
- Make 20% to 30% more spot welds than there were holes drilled.
- Plug weld the holes areas of the dashboard lower and damper housing with a MIG welder.
10. Weld the wheelhouse upper member.
When the upper member is to be reused, make MIG welds at the drilled holes.
11. Finish the welded area.
Use a hammer and dolly to even out the side bulkhead and front side frame flanges for close fit with the surface of the front wheelhouse and damper housing.
12. Apply the sealer.
Apply sealer to the mating surfaces of the lower dashboard and front side frame, etc.
13. Apply the paint.
See Paint Repair section.
WARNING:
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. Read the paint label before opening the paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
- Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.
14. Apply the undercoat.
Undercoat the front floor, etc, and apply anti-rust agent to the inside of the welding section of the front side frame, lower dashboard, and upper member.
15. Install the related parts.
Install in the reverse order in which they were removed.
16. Inspect, check and make adjustment.
- Measure the front wheel alignment.
- Inspect the brake system.
- Adjust the headlight aim.