Peugeot 308: Replacement : Front right chassis leg

Peugeot 308 2021-2025 (P5) Service Manual / Bodywork :: Front section / Chassis leg / Replacement : Front right chassis leg

ESSENTIAL : Before any operation on the structure of a vehicle fitted with a traction battery, the vehicle must be isolated by an authorised technician.

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : Observe the precautions to be taken for the pyrotechnic components .

ESSENTIAL : Any repair work carried out on a vehicle with on board electric energy (electric vehicle/hybrid vehicle) must be carried out by an authorised person.

CAUTION : All of the stripped surfaces must be protected by means of the approved electrolytic rezincing process .

CAUTION : The number of spot welds or weld beads required for assembling a new component must be identical to the number of spot welds or weld beads attaching the original component.

1. Information

Types of spot welds or beads using the electric arc process :

MIG braze welding with cupro-aluminium filler used with an inert gas
MAG welding with steel filler metal and active gas

Designation of the high strength panels :

High strength (HSS) : High strength steel
Very high strength (VHSS) : Very high strength steel
Ultra high strength (UHSS) : Ultra high strength steel

N.B. : Use the products recommended by the manufacturer .

2. Tooling

Workshop equipment :

Swan’s neck drill for cutting out electric spot welds
Hot air blower
Electronic measurement system
Mechanical measurement system

Tool	Reference	Description
	[1366-ZZ]	Toolkit for testing electric spot welds
	[1366]	Samples for testing electric spot welds
	[1126]	Set of drill bits for removing spot welds

3. Preliminary operations

ESSENTIAL : Deactivate the pyrotechnic systems .

CAUTION : Perform the operations that are required before disconnecting the ancillaries batteries .

Disconnect the ancillaries batteries (Following the specific procedure ).

CAUTION : Either remove or protect those components which are in the repair zone and risk being damaged by the heat or the dust.

Remove :

The front bumper
The headlamp
The cooling fan unit
The upper crossmember
The lower crossmember
The front half-panel support

Release the electrical harnesses.

Replace :

The front panel support
The front subframe front fixing support

4. Location : Replacement part

Identification	Description
(1)	Front right chassis leg

5. Identification of the replacement part

5.1. Composition : Front right chassis leg

Identification	Description	Thickness	Nature/classification
(1)	Front right chassis leg
(1a)	Front right chassis leg, rear section	1,95 mm	Very high strength (VHSS)
(1b)	Front right chassis leg, front section	1,76 mm	Very high strength (VHSS)
(1c)	Chassis leg end piece	3,00 mm	Very high strength (VHSS)
(1d)	Front chassis leg front partition	1,35 mm	Very high strength (VHSS)

5.2. Location : Joining on the replacement part

"A" = 192 mm (Joining zone).

Identification	Description	Thickness	Nature/classification
(1a)	Front right chassis leg, rear section	1,95 mm	Very high strength (VHSS)
(1b)	Front right chassis leg, front section	1,76 mm	Very high strength (VHSS)
(1c)	Chassis leg end piece	3,00 mm	Very high strength (VHSS)

CAUTION : Take into account the difference in thickness of the part when setting the welding station.

5.3. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Front wheel arch closing panel	1,25 mm	Very high strength (VHSS)
(3)	Front wheel arch - front part	0,95 mm	High strength (HSS)
(4)	Front wheel arch front strengthener	1,45 mm	Ultra high strength (UHSS)
(5)	Front wheel arch	1,10 mm	Very high strength (VHSS)
(6)	Bulkhead crossmember	1,75 mm	Very high strength (VHSS)
(7)	Lower bulkhead	1,15 mm	High strength (HSS)
(8)	Interior right-hand chassis leg	1,75 mm	Ultra high strength (UHSS)
(9)	Outer chassis leg	1,75 mm	Ultra high strength (UHSS)
(10)	Front right chassis leg base plate, rear section	1,95 mm	Very high strength (VHSS)
(11)	Front right chassis leg base plate, front section	1,47 mm	High strength (HSS)
(12)	Front panel support	2,00 mm	High strength (HSS)

CAUTION : Take into account the difference in thickness of the part when setting the welding station.

6. Replacement part preparation

CAUTION : When cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection.

Mark then drill to a diameter of 7 mm for later plug welding.

Prepare the mating edges and protect them using a weldable primer (index "C7").

Apply the weldable primer on the internal faces of the panels to be welded.

7. Cutting of the part on the body

Cut out the spot welds .

Cut out the spot welds (at "a").

Level off the weld bead (at "b").

Grind away the weld beads.

Remove the front right chassis leg .

8. Cleaning and preparation of the body

Prepare the mating edges and protect them using a weldable primer (index "C7").

N.B. : Apply the weldable primer on the internal faces of the panels to be welded.

9. Adjustment

Position :

The front right chassis leg
The components for adjusting

Check :

The fits and clearances
The position, using one of the approved measuring systems

Clamp the part into position.

10. Welding

CAUTION : Set the welding station.

Setting of the welding station :

Electric spot weld testing ; Using the tool [1366-ZZ]
Samples for testing electric spot welds ; Using the tool [1366]

CAUTION : The number of spot welds or weld beads required for assembling a new component must be identical to the number of spot welds or weld beads attaching the original component.