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Home >> Porsche >> 2005 >> Boxster S, Standard >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 53 - Body Rear - BOXSTER & CAYMAN >> 53 16 55 Replacing Closing Cross Member - As Of My 2005 (All Models) >> Installing Closing Cross Member >> Install closing cross member

Install closing cross member

CAUTION: Subsequent damage to the body following repair work! 
  • Rear body parts cannot be replaced without using the test gauge 9748 
  • The rear spoiler joint cannot be adjusted. 
  • The rear apron can only be fitted braced. 

→ Use the test gauge 9748 for positioning when replacing and aligning rear body parts.

→ The Boxster and Cayman have functional dimensions; body parts are positioned interdependently with very close tolerance values; parts cannot be positioned/centerd with respect to other parts.

1. Fitting closing cross member to the body

1.1. Insert the closing cross member, fit it on the side panels on the left and right.

Fig 1: Installing test gauge 9748
GP00011825Courtesy of PORSCHE OF NORTH AMERICA, INC.

1.2. Screw test gauge 9748, see Porsche special tool Workshop Equipment Manual 00000  securely to side member (impact pipe/impact absorber) -A-  . On the closing cross member, position the fastening screws for the retaining strip with the positioning sleeves -B-  and screw in positioning screws. See Fig 1.

Fig 2: Positioning square pin on light frame
GP00011826Courtesy of PORSCHE OF NORTH AMERICA, INC.

1.3. Position the test gauge with the square pin -C-  on the light frame. See Fig 2.

To complete the fit, adjust the gap clearance between rear lid and side panel according to the adjustment values. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

1.4. Secure the closing cross member with tensioning clamps.

1.5. Tack-weld closing cross member.

1.6. Remove test gauge

Fig 3: Welding in closing cross member
GP00011645Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Welding in closing cross member

2.1. Resistance spot-weld the closing cross member in areas -A, B, C-  . See Fig 3.

Fig 4: Welding in closing cross member
GP00011646Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Welding in closing cross member

3.1. Resistance spot-weld closing cross member in area -A-  and -B-  . See Fig 4.

Fig 5: Welding in closing cross member
GP00011647Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Welding in closing cross member

4.1. Resistance spot-weld closing cross member in area -A-  . See Fig 5.

Fig 6: Welding in closing cross member
GP00011648Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Welding in closing cross member

5.1. Apply a full weld to the closing cross member in area -A-  and -B-  using shielding gas. See Fig 6.

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