Chrysler Pacifica 2017 Repair Manual page 24

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NOTE: When working with aluminum use dedicated
tools, grinding discs and sandpaper to
prevent steel cross contamination with the
aluminum. Cross contamination of these two
materials will cause galvanic corrosion.
Preparation:
NOTE: When grinding the liftgate outer panel hem
flange stop immediately upon perforation.
This will prevent any grinding on the
magnesium liftgate inner panel which should
not be ground at all.
1. Remove the liftgate outer panel by grinding the outer
edge (C), with a 60 grit grinding disc, just until the
hem flange is perforated.
2. If panel is attached with adhesive you may use heat,
from a heat gun up to 204°C. (400F°). This will aid in
loosening the bond.
3. With an air chisel and a flat bladed bit, remove outer
skin and any remaining hem flange.
4. On the liftgate inner panel, with the use of 80 grit
sand paper, remove all adhesive from the area
where the structural adhesive will be applied. The
metal should be completely bare.
5. The area of the new liftgate outer panel, that will
make contact with the liftgate inner panel will need
to be scuffed with an abrasive pad . This will vary
upon adhesive manufacturers, be certain to
check adhesive manufacturer recommendations.
6. Dry fit the new panel for margin and proper
alignment. Determine where to place clamps to hold the panel in place, as necessary.
CAUTION: Be certain the fit is good from the inner panel to the outer panel and the component to the
vehicle's opening. Cured adhesive is extremely strong and will not allow for "adjustments".
7. Without a mixing tip attached, purge a small amount of structural adhesive from the cartridge. This will ensure
an even flow of both components.
8. Attach a mixing tip and dispense a mixing tube's length of adhesive from the cartridge.
NOTE: Refer to the structural adhesives manufacturer for information on work, handling and curing
times.
Installation:
9. Apply a 10 - 13 mm. (3/8 - 1/2 in.) bead of structural adhesive to bare metal mating surfaces. Use a body filler
applicator to level the adhesive, making certain to cover all bare metal to protect against corrosion.
NOTE: When applying adhesives be certain any and all drain holes remain open and clear of
obstructions.
10. Apply a second bead of adhesive to ensure proper bead thickness.
11. Position the new panel. If repositioning is necessary slide the panel, do not lift or separate panels.
Adjustments must be made by sliding, not lifting the panel(s). Apply clamps to hold panel in position, as
necessary.
NOTE: There are many tools readily available to aid in the hem flange folding process.
12. Roll the hem flange over. Remove any excess adhesive. This will save time, as compared to waiting until
cured.
13. Re-check gap and flushness to the vehicle opening and adjust as necessary.
14. Allow the adhesive to cure per manufacturer recommendations. When fully cured, expect the adhesive to be a
little tacky, as this is a normal characteristic of the adhesive. Remove clamps, if used.
15. Remove any excess cured adhesive with a grinder or abrasive disc. All adhesive must be removed from the
cosmetic repair area to ensure proper adhesion of repair and refinish materials.
31 - Collision Information
NOTE: Door skin shown. Liftgate is similar.
NOTE: Drain holes must remain clear of
obstructions from adhesives and sealers.
1 - OUTER PANEL
2 - INNER PANEL
A - STRUCTURAL ADHESIVE
B - SEAM SEALER
C - HEM FLANGE CUT LINE (BOTTOM EDGE SHOWN,
SURROUNDING EDGES TYPICAL)
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