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

2. 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

3. 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

4. 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)

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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

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

13. 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

14. 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

15. 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 over 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

16. 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

17. 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

18. 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

19. 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

20. 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

21. 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

22. 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

23. 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

24. 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 over lower front half of vehicle nose

25. 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