Peugeot 308: Replacement : Rear side member assembly

ESSENTIAL : Before any operation on the structure of a vehicle fitted with a traction battery, the vehicle must be disconnected electrical supply.

ESSENTIAL : Observe the safety and cleanliness recommendations .

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

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles (observe the regulations in force in the respective country).

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
• Mechanical measurement system
• Electronic 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 prior to a disconnection of the ancillaries battery .

CAUTION : In the case of a vehicle with 2 batteries, carry out the specific operations for disconnecting and reconnecting the ancillaries batteries.

Disconnect the ancillaries battery or batteries.

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 rear seats
• The interior trims
• The boot carpet
• The rear door
• The rear suspension
• The fuel tank

Release the electrical harnesses.

Replace :

• The partial passenger compartment side
• The rear panel assembly
• The side member rear strengthener
• The sill strengthener
• The sill web
• The rear inner wing panel front part
• The front upper side member
• The rear upper side member
• The floor/wheel arch connection
• Extension of charge load floor
• The rear suspension crossmember
• The rear wing lower closing panel

4. Location of the replacement part

Identification	Description
(1)	Rear side member assembly

5. Identification of the replacement part

5.1. Composition : Rear side member assembly

Identification	Description	Thickness	Nature/classification
(1)	Rear side member assembly	-	-
(1a)	Front lower side member	2,50 mm	High strength (HSS)
(1b)	Front side member panel	2,00 mm	Very high strength (VHSS)
(1c)	Rear side member inner panel	2,00 mm	Very high strength (VHSS)
(1d)	Rear side member end fitting	3,00 mm	Very high strength (VHSS)
(1e)	Rear lower side member	1,75 mm	Very high strength (VHSS)
(1f)	Rear lower side member extension	1,35 mm	Very high strength (VHSS)
(1g)	Rear shock absorber spring support	2,45 mm	Mild steel
(1h)	Rear interior sill	1.35 mm	Very high strength (VHSS)
(1j)	Jack guide strengthener	1,80 mm	Very high strength (VHSS)
(1k)	Rear heel mounting	2,55 mm	Very high strength (VHSS)
(1l)	Small side member/ side member connection	1,75 mm	Very high strength (VHSS)
(1m)	Rear axle support	1,75 mm	Very high strength (VHSS)
(1n)	Rear axle support strengthener	1,35 mm	Very high strength (VHSS)
(1p)	Heel plate / inner sill connection	1,75 mm	High strength (HSS)

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)	Rear floor	0,95 mm	Very high strength (VHSS)
(3)	Rear suspension support	2,50 mm	Very high strength (VHSS)
(4)	Rear wheel arch	0,80 mm	Mild steel
(5)	Lower quarter panel inner panel	1,20 mm	Very high strength (VHSS)
(6)	Inner sill	1,25 mm	Very high strength (VHSS)
(7)	Heel panel	1,15 mm	Very high strength (VHSS)
(8)	Heel plate strut stiffener	1,30 mm	Ultra high strength (UHSS)
(9)	Heel floor crossmember	0,85 mm	Very high strength (VHSS)

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").

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 .

Cut out the spot welds .

Cut out the spot welds .

Cut out the spot welds .

Cut out the spot welds .

Grind away the weld beads (at "a").

Cut out the spot welds .

Detach the rear side member assembly ; Using a hot air gun.

Remove the rear side member assembly .

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 assembled rear side member
• The components for adjusting

Check the position using one of the approved measurement 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.

Weld with electric spot welds.

Weld with plug welds.

Grind the MAG plug welds.

Weld with plug welds.

Grind the MAG plug welds.

Weld with plug welds.

Grind the MAG plug welds.

Weld with plug welds.

Grind the MAG plug welds.

Weld with MAG weld bead.

Grind the MAG weld beads.

The remaining electric spot welds will be applied during the welding of the following components :

• The partial passenger compartment side
• The rear panel assembly
• The side member rear strengthener
• The sill web
• The rear inner wing panel front part
• The front upper side member
• The rear upper side member
• The floor/wheel arch connection
• Extension of charge load floor
• The rear suspension crossmember
• The rear wing lower closing panel
• The sill strengthener assembly
• The inner sill assembly
• The quarter panel lower inner panel

11. Sealing protection

Apply :

• A layer of etch primer to the zones exposed
• Sealing mastic (index "A1")
• Anti-chip protection (index "C4")

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 .

Restore the voltage supply to the vehicle.

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

CAUTION : In the case of a vehicle with 2 batteries, carry out the specific operations for disconnecting and reconnecting the ancillaries batteries.

Reconnect the ancillaries battery or batteries.