with wrench

Figure RB18
d. Un-thread part #1 from the rivet nut.
Part #1: Un-thread from
installed rivet nut

Figure RB19

e. Perform steps 1 – 5d to install the remaining 3 rivet nuts.

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ABS
sensor
harness &
grommet

24. Reinstall the ABS sensor harness in its hole.
• Make sure the rubber grommet is in place.

Figure RB20
25. Prepare for application of LORD Fusor® 108B (P/N 999MP – 108BP) structural adhesive (see Figure RB21
and RB22).
a. Load cartridge of Fusor® 108B into the 2:1 dispensing gun.
b. Remove the cartridge cap and plugs (if this is the second use, remove the old nozzle).
c. Dispense/expel some material to make sure any hardened material is removed.
d. Install a new mixing nozzle onto the cartridge.
• Make sure the nozzle retainer is installed (see Figure RB21).
NOTE:
• Mixing nozzles are one-time use only. Do not reuse mixing nozzles.
• Two mixing nozzles are included with each cartridge of Fusor® 108B.
• Refer to the Parts Information for additional product details.
• For cleanliness, using rubber gloves is recommended.
2:1 dispensing gun
Mixing nozzle

Nozzle retainer
Load cartridge

Figure RB21

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e. Dispense 2 beads of Fusor® 108B onto a
paper that will be discarded.
•

Each bead should be about ¼ inch
diameter and about 6 inches long (length
of the nozzle).
NOTE: Performing this action will ensure
the dispenser plungers have leveled, air
bubbles have been expelled, and
adhesive is mixed correctly.
Figure RB22

26. Liberally apply Fusor® 108B to the back side of the repair bracket as shown.
• The adhesive bead should be about ¼ inch diameter in all the areas shown.
NOTE: Filling the two channels with 3 beads will ensure good adhesion in the channel area.
• It is recommended to install one repair bracket at a time after applying Fusor® 108B.

Layer 3
beads in
these two
channels

Driver side

Figure RB23

Passenger side

NOTE:
• Each cartridge of Fusor® 108B has enough material to install two repair brackets.
• Leave the nozzle attached to the cartridge between applications. The nozzle will keep the cartridge
sealed until the next use.

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27. Passenger side: Liberally apply Fusor® 108B on the strut housing area within the white line
drawn earlier (see page 24, step 20, and Figure RB24 below).
Apply Fusor® 108B
INSIDE line drawn
earlier

Slide
bracket
behind
brake
lines

RB24 – Passenger side

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28. Bolt the repair bracket into place.
• Driver side: make sure the ABS harness is pulled through its hole in the repair bracket.
• Use the correct nuts (see Figure RB25, or RB26 on next page, as it applies).
• Do not use air tools to tighten the bolts.
• Torque all new bolts/nuts to 50 N•m (5.1 kg-m, 37 ft-lb).
• Secure all existing bolts.
28a.

Make sure adhesive is cleaned from the existing threaded hole(s).

•

Driver side, see Figure RB25.

•

Passenger side, see next page, Figure RB26.
NOTE: These holes are used to mount the ABS sensor connector cover.

29. If the ratchet strap was used, carefully remove it.
30. Clean excess adhesive from around the edges of the repair bracket.

Clean excess
adhesive from
bracket edges

ABS harness pulled through

Existing threaded hole:
Clean any adhesive
from this hole

Figure RB25 – Driver side
NOTE: See additional repair bracket bolt installation information on page 33.

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8 mm bolt

Clean excess
adhesive from
bracket edges

Existing
threaded hole:
Clean any
adhesive from
this hole

Figure RB26 – Passenger side

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Additional Bolt Installation Information
Bolts that are preferred but not required (see Figure RB27):
•

If these bolts do not have enough metal to support them (make them tight), use
Lord Fusor® 108B to glue the bolts in the holes. Do not leave open holes.
These bolts are preferred for bracket support, but not required.

Bolts with rivet nuts that Must accept the torque (see Figure RB27):
•

These bolts are required and must accept the torque value of 50 N•m (5.1 kg-m,
37 ft-lb).

•

If these bolts will not accept the specified torque value, the vehicle is not repairable:
a. Retain the vehicle at the dealer.
b. Supply the customer with a rental car.
c. Fax a completed Non-Repairable Report to Morley (see page 54).

Preferred but
not required
(See
information
above)

Must accept torque

Driver side

Figure RB27

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31. Inspect the metal brake lines under the hood and in the wheel house areas for damage due to
contact with the separated strut housing.
•

If there is damage, replace the line(s).

• Refer to the appropriate Service Manual for related brake line replacement information.

32. Driver side: Inspect the brake master cylinder for
damage due to contact
with the separated strut housing.
Contact with the strut housing may have occurred
if the strut housing separated from the wheel
house.
•

If there is damage, replace the master
cylinder.
Brake
master
cylinder

• Refer to the appropriate Service Manual for
brake master cylinder replacement
information.

Figure RB28

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Patching Perforated Areas
(Level 2 repair, driver side AND passenger side – continued)
NOTE: The photo in Figure RB29 is an example of possible perforation. The vehicle you are working on
may have perforation in additional areas, areas different than these, or may not have any perforation.
If the vehicle you are working on does not have perforation, skip to step 36.
33. Cut fiberglass cloth to cover perforated areas (see example in Figure RB29).
•

Cut cloth to cover at least 1 inch beyond the perforation on all sides, except when the perforation is
next to the repair bracket.

•

Where perforation is next to the repair bracket, cut cloth to fit along the edge of the repair bracket.

•

If there is more then one perforation, cut fiberglass cloth for each perforated area.

•

Use 3M™ Bondo Fiberglass Repair Kit (P/N 422) or equivalent.

•

Use protective gloves (such as rubber gloves or disposable gloves) while working with fiberglass and
resin.

•

Do not install fiberglass patch on or over the repair bracket.
Cut fiberglass cloth to
cover at least 1 inch
beyond the perforation

Example of
perforation

Do not cover this hole.
It is used for the ABS
harness bracket.

Figure RB29

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34. Apply fiberglass patch to perforated areas.
• No additional surface preparation is needed.
¾ Apply patch over the self etching primer.
¾ Cleaning/grinding to bare metal is not needed.
• Use protective gloves (such as rubber gloves or disposable gloves) while working with
fiberglass and resin.
• Follow all warnings and cautions for the fiberglass product being used.
• Follow the product instructions for applying the fiberglass patch.
WARNING: Perform repairs in a well ventilated area.

35. Allow the fiberglass patch and resin to harden before continuing (about 30 minutes).

36. Prepare for application of LORD Fusor® 800EZ (P/N 999MP – 9G000P) seam sealer.
a. Load the cartridge into a 1:1 dispensing gun (see Figure RB30).
b. Cut the tip at about ¼ inch diameter opening.
NOTE: Refer to the Parts Information for additional product detail.

1:1 dispensing gun

Cut tip
Load cartridge
Figure RB30

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37. Apply Fusor® 800EZ (seam sealer) as shown in Figure RB31.
• Apply around the outer edges of the repair bracket. Make sure all gaps are filled.
• Apply along the seams between the strut housing panel and the wheel house.
• Use a brush or other suitable tool to smooth the sealer for good seam coverage.
• Allow seam sealer to dry for 10-15 minutes.
• Passenger side: Also apply seam sealer around the brake line junction block.
38. Driver side: Apply Butyl Sealer (P/N B6553 – 89915) around the opening for the ABS sensor harness (see
Figure RB31).
Seam between strut
housing panel and
wheel house

Outer
edge of
repair
bracket
Seal
completely
around the
junction
block

Driver side: butyl
sealer around the
hole for ABS
sensor harness

Driver side

Figure RB31

Passenger side

39. Driver side OR passenger side: Only if strut
housing panel is separated:
Apply Fusor® 800EZ (seam sealer) as shown in
Figure RB32.
• Apply along the front seam between the strut
housing panel and the wheel house.
• Use a brush or other suitable tool to smooth
the sealer for good seam coverage.
• Allow seam sealer to dry for 10-15 minutes.

Figure RB32
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40. Completely and liberally coat the area shown in Figure RB33 (strut housing and wheel house area) with
rubberized undercoat.
• Use 3M™ Rubberized Undercoating (P/N 051135 – 08883) or equivalent.
• Follow all product instructions.
• Coat all of the exposed metal areas on the strut housing and wheel house panels.
NOTE: Refer to the Parts Information for additional product details.
41. Inspect the ABS sensor harness covering – if needed use electrical tape to wrap the harness.

If needed, use
electrical tape to wrap
ABS sensor harness

Figure RB33

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42. Only if strut housing panel is separated:
Completely and liberally coat the area inside
the dashed line shown in Figure RB34 with self
etching primer.
• This is the under hood front of the strut
housing panel.
• Use DuPont Etch Primer (P/N A-4119S™)
or equivalent.
• Follow all product instructions.
NOTE: Refer to the Parts Information for
additional product details.

Figure RB34

43. Driver side: If the steering shaft needs replacement, replace it at this time.
• Refer to steering shaft inspection, step 6 on page 18.
• Refer to Steering Shaft Replacement on page 42.
44. Driver side: Reinstall the air intake duct and the air filter box.

45. Reinstall the strut in reverse order of removal.

•

Use new nuts for the upper strut mount (P/N
01225 – 00231).

•

Nut torque is:

New
nuts

39-54 N•m (4.0 - 5.5 kg-m, 29-40 ft-lb)

Figure RB35

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• Use new nuts for the lower strut mount
(P/N 54588 – ED00A).
NOTE: Reuse the original bolts.

Use
new
nuts

• Torque is:
151 – 165 N•m
(15.4 – 16.8 kg-m, 111 – 122 ft-lb)

Figure RB36

• Use a new clip for the brake line mount
(P/N 46206 – 2J00A).

New
clip

• Confirm the ABS sensor harness is
mounted correctly as shown in Figure
RB37.

ABS sensor
harness
mount

• Make sure the brake line is not twisted.

Brake line
not twisted
Figure RB37

• Use a new clip for the brake line mount
(P/N 46206 – 2J00A).

New
clip

• Make sure the brake line is not twisted.

Brake
line not
twisted

• Confirm the ABS senor harness is routed
correctly behind the strut.

ABS sensor
harness
routing

• Make sure the ABS sensor harness is
mounted correctly as shown in Figure
RB38.

ABS sensor
harness mount
Figure RB38

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•

Make sure the ABS sensor harness connector
cover is installed as shown.
¾ If the cover is missing, install a new
one.
¾ Coat the cover with 3M Rubberized
Undercoating (P/N 051135 – 08883);
don’t get any undercoat on the strut
rod.