Place it over the section to be replaced, and cut around it to remove the old floor covering.

2.15.

Remove the section to be replaced. Retain the new floor covering.

2.16.

Remove and retain the moulding pvc flooring.
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INFORMATION LETTER
2.17.

SAV.1E.2012MA

LI4223E

Remove the existing floor plywood in the repair area (see Figure 5).

Plywood to be Removed
in the Repair Area

Figure 5 - Removal of Floor Plywood

2.18.

Remove the plywood on street side and curb side wall (see Figure 6). Make sure to cut the plywood 5 mm
below the existing seam on the floor liner.
Curb Side

Street Side

Seam

Seam

Floor Covering to be
removed

Floor Covering to be
removed

Figure 6 - Removal of Plywood on Street Side and Curb Side wall

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2.19.

Remove substantial dirt, such as mud in the repair area with a spatula.

2.20.

Remove undercoating stains and other dirt using a chix cloth and cleaning product such as blitz, citrus and
ZEP 50.

2.21.

Wipe the repair area with a clean, dry and white cloth such as wypall X60.

2.22.

Let the surface dry completely and then roughen the surface by sanding it with a Scotch-Brite pad #7447B,
applying medium pressure in a back-and-forth motion, until a matt finish is obtained.

2.23.

Clean area with a clean, dry, white cloth and ZEP 50.

2.24.

Wipe off the ZEP from the structure with a clean, dry, white cloth, such as Wypall X60. Do not allow the ZEP
50 to dry on the structure surface (See Figure 7).

2.25.

Inspect the floor structure for cleanliness with another clean, dry, white cloth, such as Wypall X60. If there
are black marks on the cloth, repeat the procedure from step 2.19, else continue with the subsequent steps.
Before Cleaning

After Cleaning

Figure 7 - Typical View of Floor structure Before and After Cleaning

2.26.

Before installing brace N85122 on the floor structure, add 6 mm x 45° chamfers on brace legs as shown
(see Figure 8).
Brace N85122
Top

6x6 Chamfer

Figure 8 - Preparation of Brace

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INFORMATION LETTER
2.27.

Clean the brace N85122, using ZEP 50 and Wypall X60.

2.28.

Position the brace N85122 on the floor structure, close to the street side wall as shown (see Figure 9).

Floor Structure

Street Side

Brace N85122

Figure 9 - Typical Position of Brace on Floor Structure

2.29.

Place brace N85124 on the floor structure, leaning on the curb side wall as shown (see Figure 10) and inspect
the length of brace legs.

Street Side

Curb Side

Brace N85122
Brace N85122

Figure 10 - Inspection of Brace Leg Length

2.30.

If brace legs length are too long, reduce the brace N85124 leg length as per requirement.

2.31.

If brace legs length are too short (over 3 mm), fill the gap with the proper thickness stainless plate.

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INFORMATION LETTER
2.32.

Add 6mm x 45° chamfers on the brace N85124 legs as shown (see Figure 11).

Top

6x6 Chamfer

Figure 11 - Preparation of Brace

2.33.

Clean the N85122 brace, using ZEP 50 and wypall X60.

2.34.

Weld braces in place as per weld specification shown (see Figure12).

5 Centered Stitches
Both sides all Grooves
One Centered
Stitches

One Centered
Stitches

3 25

3 25-264
3

(3) 25

25-217
3

(3)

(3)
3
3
3
(6)

3

3 25-106

25-106

3

Figure 12 - Welding Specification

2.35.

Clean the metal floor structure using a clean towel moistened with Sika 205 cleaner. Allow 10 minutes for
drying time.

2.36.

Apply a thin and even coat of Sika 206 G+P primer on the floor structure. Allow 20 minutes for drying time.

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NOTE

The bead of adhesive is applied to the vehicle structure.
2.37.

Apply one continuous 1/2 to 3/8 in. (10 to 13 mm) bead of Sika 252 glue on the border of the area to repair
and several beads inside the area to repair.

2.38.

Adjust the dimensions of new plywood as per requirement.

2.39.

Clean the back portion of the new floor plywood using a clean towel moistened with Sika 205 cleaner. Allow
10 minutes to dry.

2.40.

Install the new floor plywood on the floor structure and side wall by applying uniform pressure.

2.41.

Remove the excess adhesive with the spatula provided.

2.42.

Install screws N56489 in the slot provided on the plywood (see Figure 13).
Street Side

Screws to be installed

Screws to be installed

New Plywood

Curb Side

Figure 13 - Installation of Screws
NOTE

If required, drill a hole as per specification shown (see Figure 14) for installing additional screws.

Figure 14 - Recommended Hole Specification

2.43.

Level the plywood irregularities and screws on the new wood floor surfaces with body filler.

2.44.

Sand the surface using a 80 Grit Pad, until the floor becomes uniform and level.

2.45.

Clean the repaired area using a clean moistened cloth such as Sika 205 cleaner. Allow 10 minutes for floor
to dry.

2.46.

Cut the moulding pvc flooring N38876 as per the old removed moulding pieces.
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INFORMATION LETTER
2.47.

Sand with a 7447B Scotch Brite pad.

2.48.

Dust with a clean and dry cloth.

2.49.

Clean the surface with a cleaning solution, such as Sika 205.

2.50.

Install the pvc moulding on the floor plywood using neoprene adhesive red N37846.

SAV.1E.2012MA

LI4223E

NOTE

The glue must be sprayed with a spray gun or with a power pump directly mounted on the adhesive container
or manually with a paint brush.
NOTE

See section 12-400: FLOOR COVERING for exact information on installation of floor covering.
2.51.

Apply contact adhesive using airless-type spray equipment to the floor covering.

2.52.

Allow approximately 15 minutes to dry until the adhesive no longer transfers to the touch joining the two
surfaces.

2.53.

Apply the new piece to the area being repaired, taking care to leave an equal space all around. Lightly flatten
the new piece.

2.54.

Glue the floor covering around the wheel house using a hammer and a wood block (see Figure 15).

2.55.

Mold the floor covering to the rubber trim and glue the floor covering to the side wall.
Apply and Push Down the Floor Covering

If the Trim Corner is Glued only on Vertical and
Horizontal faces and not to the Trim, there is a
Risk of Peeling and Trapped Air

Correct

Incorrect

Floor Covering

Rubber Trim

Floor Plywood

Floor Covering

Floor Plywood

Figure 15 - Technique for Gluing Inside Corners

2.56.

Roll the floor covering evenly with a carpet roller in order to eliminate any air pockets trapped between the
floor covering and the wooden floor. Allow 2 hours for the glue to cure and dry.

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INFORMATION LETTER
2.57.

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LI4223E

Groove the floor covering joint for the vinyl beads with a 0.08 in. (2 mm) maximum width V-shaped blade
tool (see Figure 16).
V groove width 0.08 ± 0.02 in. (2 ± 0.5 mm)

Maximum space between the floor covering
0.04 ± 0.02 in. (1 ± 0,5 mm)

Figure 16 - Recommended Bead Groove

2.58.

Prepare the hot air welding gun by installing the welding tip for a 3/16" bead and setting the heat to position
5 [662°F (350°C)].

2.59.

Use the gun to weld the joint with a vinyl bead. Let the joint cool and harden for at least 25 minutes.

2.60.

Smooth the joint and remove the excess with the spatula provided for this use (see Figure 17). Proceed to
step 2.71.

Welded Joint Before Cutting
with Spatula or Flat Plane

Welded Joint After Cutting
with Spatula or Flat Plane

Figure 17 - Welded Joint Before and After Cutting

2.61.

Apply degreaser onto the crack surface to remove undercoating.

2.62.

Apply penetrating liquid to trace the ends of the cracks.

2.63.

Drill a 3/16 inch to 1/4 inch hole at each end of the crack in order to stop the crack from growing.

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LI4223E

2.64.

Weld the crack from one end to the center and resume welding from the other end towards the center. Make
sure the hole at each end of the crack must be welded.

2.65.

Install the retained air springs and hardware.

2.66.

Install the retained mud flaps with the retained hardware.
NOTE

See section 10: TRANSMISSION AND CONTROL for exact information on installation of drive shaft.
2.67.

Install the drive shaft on the transmission.

NOTE

See section 05: REAR SUSPENSION for exact information on installation of rear axle.
2.68.

Install the retained rear axle with the retained hardware.

2.69.

Remove the jacking supports from beneath the vehicle.

2.70.

Lower the vehicle.

2.71.

Set the battery disconnect switch in the battery compartment to ON position.

2.72.

Place the Master control switch in ON position.

2.73.

The vehicle may be returned to service. 

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