Peugeot 308: Replacement : Rear wing drip moulding assembly

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

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 rear lamps
• The interior trims
• The headlining
• The rear bumper
• The rear bumper frame
• The windscreen
• The panoramic sunroof (depending on equipment)

Release the electrical harnesses.

Replace :

• The rear wing assembly
• The roof (depending on equipment)
• The roof with panoramic sunroof (depending on equipment)
• The rear roof cross member
• The rear quarter panel inner panel rear expanding insert
• The rear lamp housing expanding insert (upper part)

4. Location of the replacement part

Identification	Description
(1)	Tailgate aperture drip moulding

5. Identification of the replacement part

5.1. Composition : Tailgate aperture drip moulding assembly

Identification	Description	Thickness	Nature/classification
(1)	Tailgate aperture drip moulding assembly	-	-
(1a)	Tailgate aperture drip moulding	0,65 mm	Mild steel
(1b)	Tailgate strut fixing strengthener	1,45 mm	High strength (HSS)

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(3)	Rear wing drip moulding gusset	1,05 mm	Mild steel
(4)	Tailgate drip moulding inner panel	0,65 mm	Mild steel
(5)	Tail lamp housing	1,25 mm	Mild steel
(6)	Rear light housing closing	0,65 mm	Mild steel

CAUTION : Take into account the difference in thickness of the parts when adjusting 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").

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 .

Detach the tailgate aperture drip moulding at the beads of structural adhesive;Using the hot air blower.

Remove the tailgate aperture drip moulding .

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 tailgate aperture drip moulding
• The components for adjusting

Check the fits and clearances .

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 MAG plug welds.

Grind the MAG plug welds.

Weld :

• By means of a MAG plug weld
• With electric spot welds (at "a")

Grind the MAG plug welds.

N.B. : The remaining spot welds will be applied when welding the following component : The roof - The roof with panoramic sunroof (depending on equipment).

11. Sealing protection

Apply a phosphate-print layer to the zones laid bare.

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 ).