Peugeot 308: Replacement : Rear side member, rear part

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
• UHLE: ultra high strength steel

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

2. Tooling

Equipment :

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

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 : Deactivating 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 : Remove or protect the components that are in the repair area and that can be damaged by heat or dust.

Remove :

• The rear suspension
• The rear bumper
• The rear bumper frame
• The fuel tank
• The boot trims
• The rear mud guard

Release the electrical harnesses.

Replace :

• The rear panel assembly
• The loading floor
• The rear upper side member
• The front upper side member
• The rear floor / rear wheelarch connection
• The rear suspension crossmember
• The rear side member inner panel
• The rear shock absorber spring support

4. Location of the replacement part

Identification	Description
(1)	Rear side member, rear part(Assembly)

5. Identification of replacement parts

5.1. Composition : Rear side member, rear part (Assembly)

Identification	Description	Thickness	Nature/classification
(1)	Rear side member, rear part (Assembly)	-	-
(1a)	Rear lower side member	1,65 mm	Very high strength (VHSS)
(1b)	Rear side member end fitting	3,00 mm	Very high strength (VHSS)
(1c)	Rear lower side member extension	1,50 mm	Very high strength (VHSS)
(1d)	Rear shock absorber spring support	2,44 mm	Mild steel
(1e)	Rear side member endpiece strengthener	3,00 mm	Very high strength (VHSS)

5.2. Identification of the parts adjacent to the replacement part

Marking	Description	Thickness	Nature/classification
(2)	Front lower side member	2,50 mm	High strength (HSS)
(3)	Rear wheel arch	0,80 mm	Mild steel
(4)	Load floor extension	0,80 mm	High strength (HSS)

6. Preparation of the replacement parts

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").

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

7. Cutting of the parts on the body

Cut out the spot welds .

Level off the weld bead.

Detach the rear side member, rear part (assembly) at the beads of structural adhesive : Using the hot air blower.

Remove the rear side member rear part (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 rear side member rear part (Assembly)
• 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
• By means of MAG plug welds (at "a")

Weld with a MIG strip.

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 : Put the pyrotechnic systems into service .

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.