How to repair or replace a steel deck lid
The purpose of this procedure is to provide industry-accepted requirements for performing high-quality repair of steel deck lids. This procedure is intended for use by professionals who are qualified through training and experience.
Equipment And Material Requirements: The use of a hinge-pin removal tool is included in this procedure, use welding equipment.
Damage Analysis
Inspect a deck lid assembly for these conditions:
- visible damage
- improper previous repairs
- misalignment with adjacent panels
- reinforcements that have separated from the deck lid
- cracks at spot welds, or damaged fasteners
- damaged or missing trim, labels, seals, etc.
- missing or damaged anti-flutter materials
- damaged latch or lock cylinder
- damaged hinges or torsion rods
- damaged lamp or reflector assembly
Determine if the deck lid is to be repaired or replaced. Verify the availability of replacement parts. If there is severe damage to the hinge or striker mounting areas, the deck lid should be replaced.
Personnel Safety
Make sure the deck lid is properly supported, and use proper lifting techniques during removal and installation. Torsion rods and spring-loaded hinges are under tension. Use special caution when working on deck lids equipped with torsion rods or spring- loaded hinges.
When working with a steel deck lid:- Protect the deck lid to prevent further damage during the repair.
- Protect adjacent panels and glass from damage.
Deck Lid Repair
1. Remove the inner trim panel, if required for access.
2. Perform repairs using metal repair and heat shrinking procedures,as appropriate.
3. Replace damaged welded-on trim-mounting studs, if required.
4. Apply corrosion-resistant primer to all interior and exterior surfaces damaged by the collision or repairs.
5. Check the deck lid alignment. Adjust if required.
6. Refinish the deck lid to restore the appearance, including edges damaged by the collision or repairs. Refinish cosmetic surfaces after all body repairs are complete.
7. Replace or restore sound deadeners, anti-flutter materials, etc., that were damaged by the collision or repairs.
8. Install the inner trim panel.
9. Replace all trim, labels, weatherstrips, etc.
10. Continue vehicle reassembly.
Deck Lid Removal
1. Open and support the deck lid.
2. Protect the backlite and adjacent panels.
3. Disconnect the electrical connectors, cables, hoses, and torsion rods, if required.
4. Mark the hinge positions on the deck lid, and on the body panel if the hinges are being replaced. Use existing painted surfaces as a reference.
5. Unfasten the deck lid from the hinges. Note the location of any shims.
6. Carefully remove the deck lid from the vehicle.
7. Remove the striker assembly.
Deck Lid Installation
1. If installing a replacement deck lid, refinish the underside and edges of the deck lid before installation.
2. Protect the backlite and adjacent panels.
3. Support the deck lid on the hinges and loosely install the fasteners. Reinstall any removed shims.
4. Lower the decklid slowly. Make sure it does not contact the adjacent panels.
5. Check for proper alignment to the adjacent panels. Adjust the position at the hinges as needed.
6. Raise the deck lid and properly torque all fasteners to the vehicle makers recommendations.
7. Close the deck lid and recheck the alignment.
8. Install the striker assembly.
9. Lower the deck lid slowly to see if the striker properly enters the latch assembly without forcing the deck lid out of alignment. Align the latch assembly, or the striker as needed.
10. Reconnect the torsion rods, electrical connectors, cables, and hoses.
11. Spot paint the hinges and fasteners, if required.
12. Refinish the deck lid, if required. Refinish cosmetic surfaces after all body repairs are complete.
13. Transfer or install replacement parts such as handles, lock cylinders, etc.
14. Install trim, labels, weatherstrips, seals, etc.
15. Lubricate the hinges and latch, if required. Follow the vehicle makers recommendations.
16. Test all electrical accessories for proper operation.
17. Perform water leak tests to ensure proper sealing.
18. Continue vehicle reassembly.
Use Of Recycled (Salvage) Parts
Condition Of Salvage Parts
Do not install a salvage steel deck lid having any of these defects:- unrepairable damage
- corrosion that has caused pitting
- improper previous repairs
- reinforcements that have separated from the deck lid
Replace any damaged or missing trim, labels, seals, latches, etc. Confirmthat all labels or information decals match the original. Replace if required.
Inspection And Testing
Inspection Of A Repaired Or Replaced Steel Deck Lid
After installation or repair, inspect a steel deck lid for these conditions:- proper alignment with adjacent panels
- fasteners torqued to the vehicle maker's recommendations
- proper application of anti-flutter materi
- proper lubrication of the hinges, latch, and lock cylinder
- proper operation of the lock cylinder
- proper operation of the torsion
- proper latching and release
- proper finish appearance and film thickness
- proper installation of all trim, labels, and fasteners
- proper installation of hoses, cables, wiring, and electrical connectors
- proper operation of electrical accessories
- proper sealing against air and water leaks
