Removing Rear Side Member (Section)

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 (Section)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Rear side member (section)
Floor section, left
Support

Remove end plate. → Removing End Plate
Remove lock carrier. → Removing Lock Carrier
Remove spare-wheel well. → Removing Spare-Wheel Well

Fig 2: Overview Of Side Member (Behind)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Separate floor section.
1. 4.1. Grind off welded joints on the floor section using a parting grinder (area -A- ).
  
  Fig 3: Separating Welded Joints On Floor Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 4.2. Mill off welded joints on the floor section using the spotweld cutter (areas -A and B- ).
  
  Fig 4: Separating Welded Joints On Floor Section
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 4.3. Heat up sealing areas on the floor section uniformly using a hot-air blower (areas -A- ).
  
  Fig 5: Heating Up Sealing Areas
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 4.4. Heat up bonding area of seal uniformly using a hot-air blower (area -B- ).
Remove floor section.

Fig 6: Overview Of Side Member (Behind)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Separate rear side member at the bottom of the D-pillar.
1. 6.1. Grind off MIG seams on the D-pillar using a parting grinder (area -A- ).
  
  Fig 7: Separating Welded Joints On D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 8: Overview Of Side Member - Inside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut through rear side member.
Information
- Separating the side member involves cutting through the complete side member as well as the support attached to the outside.
1. 7.1. Cut through the rear side member in area -A- using the body saw. Maintain the dimension -X1- → Cut dimension, old part: 220 mm .
  
  Fig 9: Cutting Through Rear Side Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 10: Overview Of Side Member - Outside
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Separate rear side member at the bottom of the D-pillar from the outside.
1. 8.1. Separate the rear side member from the bottom of the D-pillar by making a rough cut in area -A- using the body saw.
  
  Fig 11: Separating Rear Side Member From D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove rear side member.

Fig 12: Overview Of Side Member - Outside
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off remaining piece of support on the side member.
1. 10.1. Mill off welded joints on the support using the spotweld cutter (area -A- ).
  
  Fig 13: Separating Welded Joints On Support
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove remaining part of support.

Fig 14: Overview Of Side Member - Inside
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Separate remaining part of side member on the bottom of the D-pillar.
1. 12.1. Mill off welded joints on the bottom of the D-pillar using the spotweld cutter (area -A- ).
  
  Fig 15: Separating Welded Joints On Bottom Of D-Pillar
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove remaining piece of side member.