Removing Rear Side Member

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

Information

All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be completed before the damaged parts are removed .

Fig 1: Rear Side Member Component Location
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Floorpan, centre left
Rear side member
Left floor section (luggage compartment)

Remove end plate. → Removing End Plate
Remove lock carrier. → Removing Lock Carrier
Remove rear side section. → Removing Rear Side Panel
Remove (outer) rear wheel housing. → Removing Rear Wheel Housing
Remove (inner) rear wheel housing. → Removing Rear Wheel Housing
Remove D-pillar reinforcement. → Removing D-Pillar Reinforcement

Fig 2: Overview Of D-Pillar - Outside
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut lid out of centre floorpan.
1. 7.1.
  Information
  - Only the upper floorpan can be cut through during the separation process. The front edge of the round opening in the floorpan is used as the rear reference line for taking measurements.
  Information
  - Only the upper floorpan can be cut through during the separation process.
  Cut a lid out of the centre floorpan in areas -A, B and C- using the oscillating body saw. Maintain the dimensions -X1 and X2- → Cut dimension, old part: 300 mm → Cut dimension, old part: 150 mm . Do not damage internal components.
  
  Fig 3: Cutting Lid Out Of Centre Floorpan
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Mill off welded joints on the lid on the centre floorpan using the spotweld cutter (areas -A and B- ).
  
  Fig 4: Separating Welded Joints On Centre Floorpan Lid
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 7.3. Grind off MIG seam on the lid on the centre floorpan using a parting grinder (area -C- ).
4. 7.4. Remove lid on centre floorpan -1- by pulling it upwards -Arrow- .
  
  Fig 5: Locating Centre Floorpan Lid
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut lid out of rear floorpan.
Information
- Only the upper floorpan can be cut through during the separation process.
Information
- Only the upper floorpan can be cut through during the separation process. The front edge of the floorpan is used as the front reference line for taking measurements.
1. 8.1. Cut a lid out of the rear floorpan in areas -A, B and C- using the oscillating body saw. Maintain the dimensions -X3 und X4- → Cut dimension, old part: 90 mm → Cut dimension, old part: 110 mm . Do not damage internal components.
  
  Fig 6: Cutting Lid Out Of Rear Floorpan
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Information
  - The separated lid from the rear floorpan is re-used during installation.
2. 8.2. Remove lid on rear floorpan -1- by pulling it upwards -Arrow- .
Cut off rear side member through the opening in the floorpan.
1. 9.1. Grind off MIG seams on the side member from above using a parting grinder (areas -A and C- ).
  
  Fig 7: Separating Welded Joints On Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 9.2. Grind off MIG seams on the side member from above using a parting grinder (areas -B and D- ).
  
  Fig 8: Overview Of Side Member (Below)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off side member at the spare-wheel well.
1. 10.1. Mill off welded joints on the spare-wheel well using the spotweld cutter (area -A- ).
  
  Fig 9: Separating Welded Joints On Spare-Wheel Well
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 10: Overview Of Side Member (Behind)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off side member at the rear floorpan.
1. 11.1. Grind off welded joints on the rear floorpan- starting from below - using a parting grinder (area -A- ).
  
  Fig 11: Separating Welded Joints On Rear Floorpan
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 11.2. Mill off welded joints on the rear floorpan using the spotweld cutter (area -B- ).
Cut off part of floor section (luggage compartment).
1. 12.1. Cut through the floor section by making a rough cut in area -A- using the oscillating body saw.
  
  Fig 12: Separating Floor Section (Luggage Compartment)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 12.2. Grind off welded joints on the floor section using a parting grinder (area -B- ).
3. 12.3. Mill off welded joints on the floor section using the spotweld cutter (area -C- ).
4. 12.4. Remove separated part of floor section -1- by pulling it upwards.
  
  Fig 13: Overview Of Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off side member from outside.
1. 13.1. Mill off welded joints on the side member using the spotweld cutter (areas -A and B- ).
  
  Fig 14: Separating Welded Joints On Outer Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 15: Overview Of Side Member (Behind)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off side member at the rear floorpan.
1. 14.1. Mill off welded joints on the rear floorpan using the spotweld cutter (area -A- ).
  
  Fig 16: Separating Welded Joints On Rear Floorpan
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 17: Overview Of Side Member (Outside)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off side member at the centre floorpan.
1. 15.1. Mill off welded joints on the centre floorpan using the spotweld cutter (areas -A and B- ).
  
  Fig 18: Separating Welded Joints On Centre Floorpan
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 19: Overview Of Side Member (Below)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off centre side member joints.
1. 16.1. Drill off welded joint on the side member from below by drilling through all panel thicknesses (area -A- ).
  
  Fig 20: Separating Welded Joints On (Outer) Centre Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 16.2. Grind off welded joints on the side member using a parting grinder (area -B- ).
3. 16.3. Mill off welded joints on the side member using the spotweld cutter (area -C- ).
4. 16.4. Drill off welded joint on the side member from below by drilling through all panel thicknesses (area -A- ).
  
  Fig 21: Separating Welded Joints On (Inner) Centre Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 16.5. Mill off welded joints on the side member using the spotweld cutter (area -B- ).
6. 16.6. Grind off MIG seams on the side member using a parting grinder (areas -A and B- ).
  
  Fig 22: Separating Welded Joints On (Outer And Inner) Centre Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 23: Overview Of Side Member (Below)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off side member at the inner lower side member.
1. 17.1. Mill off welded joints on the inner lower side member (centre) using the spotweld cutter (area -A- ).
  
  Fig 24: Separating Welded Joints On Inner Lower Side Member (Centre)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 17.2. Mill off welded joints on the inner lower side member (centre) using a parting grinder (area -B- ).
3. 17.3. Mill off welded joints on the inner lower side member (rear) using a parting grinder (areas -A and B- ).
  
  Fig 25: Separating Welded Joints On Inner Lower Side Member (Rear)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 17.4. Mill off welded joints on the inner lower side member (rear) using the spotweld cutter (area -C- ).
  
  Fig 26: Overview Of Side Member (Below)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off side member at the cross member.
1. 18.1. Mill off welded joints on the cross member using the spotweld cutter (areas -A and B- ).
  
  Fig 27: Separating Welded Joints On Cross Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 28: Overview Of Side Member (Below)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off side member at the floorpan.
1. 19.1. Mill off welded joints on the floorpan using the spotweld cutter (areas -A and B- ).
  
  Fig 29: Separating Welded Joints On Floorpan
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 30: Overview Of Side Member (Behind)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Heat up sealing areas on the floorpan and loosen side member.
1. 20.1. Heat up sealing areas on the floorpan uniformly using a hot-air blower (area -A- ).
  
  Fig 31: Separating Sealing Areas On Rear Floorpan
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 20.2. Heat up sealing areas on the floorpan uniformly using a hot-air blower (areas -A, B and C- ).
  
  Fig 32: Separating Sealing Areas On Centre Floorpan
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove side member.