Chapter 12 Replacing Hoods Bumpers Fenders Grilles and

Chapter 12 Replacing Hoods, Bumpers, Fenders, Grilles, and Lids

Objectives • Remove and install fenders • List the various methods for adjusting mechanically fastened panels • Perform hood-to-hinge, hood height, and hood latch adjustments • Remove, install, and adjust deck lids • Remove, install, and adjust bumpers • Replace grilles and other bolt-on body parts

Introduction • Repair steps depend on nature and location of damage • Panels with minor damage can often be straightened and filled with body filler • Minor bulges, dents and creases can be fixed using techniques discussed in earlier chapters • If damage is too great, parts must be replaced • When replacing several adjoining parts, you must properly align all parts

How Are Parts Fastened? • Methods of fastening parts to cars and trucks has changed in the past few years • Fastener variations can make repair more challenging • Inspect parts closely to find out how they are held onto vehicle • On-the-job experience is the only way to become competent and fast at body part removal and replacement (R and R)

Figure 12 -2. Note some of the parts that bolt onto this unibody vehicle.

Refer to Estimate • When starting to work, refer to estimate to get guidance on where to begin • Estimator will have determined which parts need repair and which should be replaced • Estimate is an important reference tool for doing repairs and it must be followed • Estimate is also used to order new parts • Compare new parts on hand with parts list, and if necessary have parts person order

Where to Start • Generally, remove large, external parts first – More light and room for accessing internal parts • If in doubt about how to remove a part, refer to vehicle’s service manual • Body repair section of manual explains and illustrates how parts are serviced • Manual gives step-by-step instructions, bolt locations, torque values, removal sequences

Hood Removal and Replacement • Hood is one of the largest heaviest panels • First disconnect wires and hoses, next remove hinged bolts, mark hood hinge alignment • Have someone help you hold hood, place your shoulder under hood while holding bottom edge with one hand • With free hand, remove hood bolts – do not let weight of hood rest on bolts

Hood Hinge Removal and Replacement • Hood hinges allow hood to open and close while staying in alignment • If hood has large coil springs you may have to install old springs on new hinges • A hood spring tool should be used to stretch spring on and off – Hooked tool that easily pries end of spring off of and onto its mount

Hood Adjustment • Install hood in reverse order of its removal • Adjust hood before tightening bolts fully • After installing, close it slowly; if not centered it could hit and dent fenders • Hood adjustments are made at the hinges, at the adjustable stops and at hood latch • Hood can be adjusted up, down, forward, or rearward

Hood Adjustment (continued) • Hood hinge adjustments control general position of hood in fenders and rear hood height • There should be enough of a gap at back edge to clear cowl panel – A gap is the distance between two parts • Hood stop adjustment controls height of front of hood • Adjust hood stops so that hood is even with front of fenders and fascia

Figure 12 -5. The gap around the hood should be the same. The problems may be due to fenders being out of alignment.

Hood Latch Removal, Replacement and Adjustment • Hood latch mechanism keeps hood closed and releases hood when activated • Hood release handle can be pulled to slide a cable running out to hood latch • Hood latch has metal arms that grasp and hold hood striker • When cable release is pulled, hood latch arms release striker so hood can open

Hood Latch Removal, Replacement and Adjustment (continued) • Hood striker bolts to hood and engages hood latch when closed • Before removing a hood latch, scribe mark its location, remove bolts and disconnect any cable • Adjust latch – it should produce a slight compression of rubber stops • Tighten latch bolts, make sure latch releases hood properly

Bumper Removal, Replacement and Adjustment • Many bumpers use an outer covering of flexible plastic with a steel or aluminum inner bumper • Some have a plastic honeycomb or foam structure behind their flexible cover • Many have a large one-piece cover lower front half of vehicle nose • To remove a bumper first disconnect wiring to any lights – refer to service manual • Support bumper before removing last mounting bolts

Bumper Removal, Replacement and Adjustment (continued) • If bumpers are to be repaired or reused, place a block of wood on jack saddle • Raise jack to support bumper weight, and remove bolts • Bumper shock absorbers compress inward to help prevent bumper damage • When bumper shock absorbers are used, bolts or nuts on shocks often hold bumper in place • Sometimes it is best to remove large assemblies

Fender Removal, Replacement and Adjustment • To remove fender, find and remove all fasteners, and any wires going to fender mounted lights • Fenders are usually bolted to radiator core support, inner fender panels and cowl • Install replacement fender in reverse order • If doors or cowl are undamaged, place masking or duct tape over their edges • Fender shimming uses spacers under bolts to position fender for proper alignment

Grille Removal and Replacement • Grilles are often held in place with small screws, rivets, and clips • Air ratchet is handy for reaching down and unscrewing grille bolts • Make sure all clips are undamaged and installed • Most grilles are plastic; be careful not to overtighten any bolts or screws • Some grilles can be adjusted – They have slotted or oversized holes in them

Deck Lid Removal, Replacement, and Adjustment • Deck lid removal is similar to hood removal • Latch must be adjusted so that it holds lid or hatch closed against weatherstripping • To remove lock cylinder, pry retainer sideways, – If necessary, lubricate with graphite • Lid struts are spring-loaded gas-filled units that hold lid open so it will close more slowly • Lid torsion rods extend horizontally across body and engage a stationary bracket

Panel Alignment • After installing all new body panels you must check overall panel alignment • Make sure that clearance between panels is equal, and that gap is within specifications • Check that panel surfaces are even with each other • Take time to double-check all panels to ensure good alignment – this is a sign of a professional technician

Truck Bed Removal and Replacement • Truck beds are usually bolted to frame – To remove bed, simply remove bolts • Keep track of bolt lengths and rubber mounting cushion locations – They must be reinstalled to original locations • Truck tailgates mount on two hinges – Latches in tailgate engage strikers in body • Truck tailgates are surprisingly heavy – Ask for help when removing or installing one

Installing Sound-Deadening Pads • Sound-deadening pads are often bonded to inside surface of trunk cavities and doors • Sound-deadening material is made of plastic or asphalt-based material • Sound-deadening pads must be replaced to match precollision performance • Some pads are available as factory service parts • One sound-deadening product is available with an adhesive back, cut it to size and shape

Summary • When starting work, refer to estimate to get guidance on where to begin • Estimator will have determined which parts need repair and which should be replaced • Hood hinges allow hood to open and close while staying in alignment – Hold considerable weight while keeping hood open, and are often damaged in frontal impact

Summary (continued) • Cable hood release consists of hood release handle, hood release cable, hood latch and hood striker • Bumpers are designed to be light yet strong – Many use an outer covering of flexible plastic with a heavy steel or aluminum inner bumper – Some have a plastic honeycomb structure – Trend is a large one-piece cover lower front half of vehicle nose

Summary (continued) • Fender shimming is an adjustment method that uses spacers under bolts that attach fender to the cowl or inner fender panel • By changing shim thickness, you can move position of fender for proper alignment • After installing all new body panels, check overall panel alignment • Make sure clearance between panels is equal and that gap around all parts is to specifications