There is now an approved procedure to replace the front chassis rails on the Holden VE/WM series vehicles. Damage to the front chassis rail can be repaired by sectioning or replacing the complete rail if required in accordance with the Holden Body Repair manual.

Vehicles should only be repaired using the procedures outlined in the GM-Holden Body Repair information available online at;

http://www.acdelcotds.com/acdelco/action/home  

Parts numbers applicable for the front rail repair are as follow:
LHS P/N 92194474
RHS P/N 92194473
For further assistance contact the IAG Research Centre on (02) 92926840

Body side assemblies for MY12 VE/WM vehicles have an internal difference compared to all production up to and including MY11.

MY 11 and prior body side assemblies cannot be used to repair a MY12 vehicle, due to changes in the side impact sensor and the sheet metal in the lower B pillar area.

When stock of the earlier body side assemblies is exhausted, repair of MY07, 08, 09, 10, 11 VE/WM vehicles will require the MY12 body side assembly plus an adaptor piece for mounting the side impact sensor. Part numbers are shown on the table below.

The original part numbers can be used for MY07 to MY11 vehicles until stock is exhausted.

Note that GM-Holden does not authorise replacement of the outer quarter panel skin on VE utility by cutting the door aperture. (There is an authorised method for VE Sedan, VE Sportwagon and WM sedan.)

Holden is currently working on a solution for VE utility to contain replacement costs.

For further information please contact the IAG Research Centre on (02) 9292 6840

Acknowledgement: Information supplied by GM-Holden

It is important to refer to the GM Holden repair manual to ensure the sectioning procedure is carried out as per GM Holden specifications.

Once the damaged front chassis rail section has been cut and removed, the new chassis rail will need to be trimmed to suit. A staggered joint repair method has to be performed between the new chassis rail section and the rear section of the existing chassis rail.

Once the new chassis rail section has been trial fitted and aligned to the existing rear section of chassis rail, welding can be carried out.

Spot welding is the preferred method for attaching panels and should be used wherever possible. A plug weld should be performed where the spot welder is unable to reach.

When performing seam-welding, care must be taken to minimize excessive heat buildup. This is to avoid distortion. Also, excessive heat can alter the structure and integrity of HSS panels.

We suggest an allowance of 4.5 hours, which includes the removal and replacing of the skirt brace.

Should you have any further enquiries regarding this bulletin please contact the IAG Research Centre (02) 9292 6843.

The Holden VE Commodore Ute Body side outer panel was recommended to be replaced as a whole assembly until recent revisions of the procedure.

Now there is a new recommended procedure in the replacement of the body side outer panel. If the Body side outer panel damage is from the wheel arch at a specified point rearward on vehicle, the panel can be replaced as a Quarter panel outer section (picture shown on next page).

However, if the Body side outer panel is damaged forward of the specified point the complete Body side panel assembly still requires replacement (picture shown on next page).

A Body Repair manual with the recommended replacement procedure and a Body side outer panel short section part will be available through Holden Dealers in the near future (approximately November for the part). In the meantime, Repairers and Assessors should contact the IAG Research Centre.

For any further information please contact the IAG Research Centre on (02) 9292 6840.

Acknowledgement: Information supplied by General Motors/Holden.

The lower edge of the rear bumper fascia is attached to these lugs with plastic retainers.

Minor rear impacts can transfer high loadings to the lugs, which will then typically fail.

The lugs cannot be plastic welded because they are fibre-reinforced composite.

The wheel well itself is bonded into the rear of the body shell. It is difficult and time consuming to remove and replace.

The IAG Research Centre has designed metal brackets which can be fitted over the damaged lugs to avoid having to remove and replace the entire wheel-well. These brackets reduce the cost of repairs enormously and also preserve the integrity of the original factory wheel well installation.

The following steps outline the method developed at the IAG Research Centre to restore damaged lugs to their original strength and function.
These steps should be followed closely to ensure similar future impact performance is achieved.
Note:
• Latex gloves should be worn during this operation
• The work can be done with the vehicle at ground level, or raised on a hoist

There are 14 steps:

1. Detach the rear bumper bar plastic facia and the plastic clips from the lug(s) to be repaired.
2. Remove any broken or hanging debris from the damaged lug(s).

3. Using a panel file or similar, carefully remove the ‘lip’ on the back edge of the lug(s). Ensure that the lug itself is not filed.

4. Using 180-200 grit abrasive paper, scuff each exterior surface of the damaged lug(s).
5. Clean the exterior of the damaged lug(s) with Prepsol or similar solvent to remove dust, grease or fibres.
6. Using a 180-200 grit abrasive paper, scuff each interior surface of the replacement bracket(s).
7. Clean the interior of the replacement bracket(s) with Prepsol or similar solvent to remove dust, grease and paint powder.
8. Check-fit the lug(s) to the appropriate bracket(s). To achieve a better fit with the lug(s), bend the sides of the bracket(s) in or out, as required. There should be a 1-2mm gap between the bracket and the lug surfaces for adhesive.
9. Apply Sika® Sikaflex-206 G&P surface primer to the interior surfaces of bracket(s) and exterior surfaces of lug(s) and allow to dry, according to product instructions.
10. Apply Sika® Sikaflex-206 adhesive to the interior bracket bonding surface.
11. Push bracket(s) onto lug(s) and remove excess adhesive.
12. Insert a plastic fascia fastener into the lug, to hold the bracket in place.
13. Apply the adhesive tape over the bracket(s) whilst Sika flex is curing. Allow the adhesive 48 hours to cure completely.

14. After the adhesive has completely cured, remove the adhesive tape and plastic fastener. Inspect the repair by checking for movement of the bracket. The bracket should feel quite rigid, but with a very small amount of flex (from the adhesive). The rear bar can now be reattached to the vehicle in the normal manner.