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Home >> Porsche >> 2014 >> Boxster S, Automatic DCT Trans >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> 53 - Body Rear - BOXSTER & CAYMAN (981) >> WM 530255 Replacing Rear End (Except BOXSTER GTS, BOXSTER SPYDER) >> Preparing Rear End For Installation

Preparing Rear End For Installation

  1. Fit in rear end and secure it to the body. Check gap dimensions. →  5X00IN DIAGRAM - BODY GAP DIMENSIONS  . 

    Position the rear end using the straightening system.

    1. 1.1. Drill bores for the rivets in area -A-  through the existing holes. → Diameter: 6.6 mm 
    2. 1.2. Drill new hole for ground connection in area -B-  . → 5X00IN25 MAKING GROUND CONNECTIONS .→ Diameter: 9 mm 
    3. 1.3. Drill new holes in area -C-  . → Diameter: 6.6 mm 
      G10023223Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Drill the holes on the front edge for reasons of accessibility.

  2. Drill new holes in area -D-  . → Diameter: 6.6 mm 
    1. 2.1. Drill holes for rivets in area -A-  through the existing holes. → Diameter: 6.6 mm 
      G10023224Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Drill the holes around 10 mm lower for reasons of accessibility.

  3. Drill new holes in area -D-  . → Diameter: 6.6 mm 
    1. 3.1. Drill holes for rivets in area -A-  through the existing holes. → Diameter: 6.6 mm 
      G10023225Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Install filler plates.
    1. 4.1. Fit in filler plates and secure them to the body.
    2. 4.2. Drill new holes in area -A;D-  . → Diameter: 6.6 mm 
      G10023226Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Remove rear end.
  6. Prepare connection areas on the rear end. → Preparing Bonding Surfaces .
    G10023227Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    G10023228Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Blue Bonding + resistance spot-welding
    Orange Bonding + riveting
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