Front side member and upper suspension support assembly (Freelander 2)

Contents: Removal ⇩ Installation ⇩

NOTE: The front spar and upper suspension mount assembly includes the spar end panel, wing apron panel reinforcement, wing apron panel front extension, wing apron lower panel, front spar and wing apron panel, and upper suspension mount.

NOTE: The service panel is not fully welded.

NOTE: The panel is serviceable without its mounting studs.

Removal

1. In combination with the front side member and upper suspension support assembly, the following is replaced:

Front bumper trim
Front bumper mount
Hood Latch Panel
Both front wings
Front bumper mount
Upper panel of the wing apron
Front spar

2. For additional information regarding this repair procedure, refer to: For additional information, refer to: Body and Frame (501-26 Body Repairs - Special Vehicle Information and Tolerance Checks, Description and Operation) / Standard Service Station Techniques (100-00 General Information, Description and Operation).

3. Remove the front side member. For more information, refer to the chapter: Front Side Member (501-27 Front Sheet Metal Repairs, Removal and Installation).

4. Remove the upper mudguard panel. For more information, refer to the chapter: Upper Mudguard Panel (501-27 Front Sheet Metal Repairs, Removal and Installation).

5. Remove the instrument panel. For more information, refer to the chapter: Control panel - 2.2L Duratorq - Td4 (501-12 Instrument panel and console, Removal and installation).

6. Remove the interior trim of the lower trim panel.

7. Remove the lower B-pillar trim. For more information, refer to the chapter: Lower B-pillar trim panel (501-05 Interior Trim, Removal and Installation).

8. Release and position aside the front carpet section.

9. Release and place aside the insulation material on the outer partition.

10. Left side: Remove the hood release handle.

11. Right side: Remove the brake booster. For more information, refer to the chapter: Brake Booster (206-07 Brake Booster, Removal and Installation).

12. Right side: Remove the pedal assembly.

13. Release and place aside the wiring harnesses for the A-pillar, bulkhead and side member.

14. Mill out the weld spots.

15. Separate the connections and remove the old panel.

Installation

1. Prepare a new panel in the areas of incomplete welding and perform MIG welding in these areas.

2. Prepare the connecting surfaces of the old and new panels.

3. Drill holes in the new panel for MIG welding.

4. Apply the new panel and fix it in place. Check the alignment, if correct, proceed to the next step, if not, correct and check again before proceeding to the next step.

5. MIG welding.