Peugeot 308: Replacement : Bulkhead crossmember

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. Tools

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 power unit
• The suspension
• The dashboard
• The bulkhead soundproofings

Release the electrical harnesses.

Replace :

• The front chassis legs
• The front panel supports
• The front fixing supports of the front subframe

4. Location of the replacement part

Identification	Description
(1)	Bulkhead crossmember

5. Identification of the replacement part

5.1. Composition : Bulkhead crossmember

Identification	Description	Thickness	Nature/classification
(1)	Bulkhead crossmember	1,75 mm	Very high strength (VHSS)

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

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Lower bulkhead	1,15 mm	High strength (HSS)
(3)	Closing panel	1,25 mm	Mild steel
(4)	Outer chassis leg	1,75 mm	Ultra high strength (UHSS)

6. Preparation of the replacement parts

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

Drill to a diameter of 7 mm for later MAG plug welding.

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.

7. Cutting of the part on the body

Cut out the spot welds .

Detach the bulkhead crossmember at the beads of structural adhesive ; Using the hot air blower.

Remove the bulkhead crossmember .

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.

Apply a structural adhesive index "B3".

9. Adjustment

Position :

• The bulkhead crossmember
• The components for adjusting

Check :

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

Support the parts in 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.

Weld with MAG plug welds.

Grind the plug welds.

11. Sealing protection

Apply :

• A layer of etch primer to the zones exposed
• Sealing mastic (index "A1")

Painting, then spraying of the index "C5" product into the hollow sections in the repair zone.

12. Additional operations

Refit the electrical harnesses and reinstall all removed components.

13. Reinitialisation

ESSENTIAL : Reactivate the pyrotechnic systems .

CAUTION : Perform the operations that are required after reconnecting the ancillaries batteries .

Reconnect the ancillaries batteries (Following the specific procedure ).