Nissan Armada 2025-2026 Service and Repair Manual: Replacement Operations

Precautions for Body Repair

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

WARNING:

Description

• Technicians are encouraged to read the Body Repair Manual (Fundamentals) in order to ensure that the original functions and quality of the vehicle are maintained. The Body Repair Manual (Fundamentals) contains additional information, including cautions and warnings, that are not including in this manual. Technicians should refer to both manuals to ensure proper repair.

• Please note that this information is prepared for worldwide usage, and as such, certain procedures might not apply in some regions or countries.

The symbols used in this section for welding operations are shown below.

Symbol marks	Description
″Number″	″Number″ after symbol mark is the total number of welds to apply. Example 1: ″4″A = 4 MIG plug welds for 3-panel plug weld method. Example 2: ″1″× 20 (0.79) = 1 MIG seam weld by length 20 mm (0.79 in).
	2-panel spot weld
	3-panel spot weld
	MIG plug weld
		For 3-panel plug weld method
	MIG seam weld / Point weld
	Rivet

• Front pillar butt joint can be determined anywhere within shaded area as shown in the figure. The best location for the butt joint is at position A due to the construction of the vehicle.

  

• Determine cutting position and record distance from the locating indent. Use this distance when cutting the service part. Cut outer front pillar over 60 mm (2.36 in) above the inner front pillar cut position.

  

• Prepare a cutting jig to make outer pillar easier to cut. Also, this will permit the service part to be accurately cut at the joint position.

  

• An example of cutting operation using a cutting jig is as per the following.

  

1. Mark cutting lines.

   A: Cut position of outer pillar

   B: Cut position of inner pillar

2. Align cutting line with notch on jig. Clamp jig to pillar.

3. Cut outer pillar along groove of jig (at position A).

4. Remove jig and cut remaining portions.

5. Cut inner pillar at position B in same manner.

Welding of Ultra High Strength Steel

SPOT WELDING

Spot welding is limited to ultra high strength steel (tensile strength: 980 MPa) according to the welding conditions listed below.

CAUTION:

• If the below welding conditions cannot be met, then perform plug welding.

• Never spot weld ultra high strength steel of tensile strength more than 980 MPa. For this type of ultra high strength steel, perform plug welding.

• The below welding condition is applicable only to this vehicle. Never apply this same welding condition to other vehicles.

Welding condition

Welder tip diameter	6 mm
Welding pressure (Gun force)	3300 N
Panel configuration	Combination of a plate of tensile strength 980 MPa and that of tensile strength less than 980 MPa. (Up to 3 plates)
Welding current and weld time

		Welding current	Weld time		Welding pressure (Gun force)	Description
			50 Hz	60 Hz
	Before welding	0 A	-	-	0 N	-
	First energization	7000 A	0.04 sec (2 cycle)	0.05 sec (3 cycle)	3300 N	Secure an energization path
	Cool down	0 A	0.02 sec (1 cycle)	0.02 sec (1 cycle)	3300 N	-
	Second energization	7500 A	0.12 sec (6 cycle)	0.12 sec (7 cycle)	3300 N	Main energization for nugget formation
	Keep pressurization	0 A	0.10 sec (5 cycle)	0.08 sec (5 cycle)	3300 N	-
	After welding	0 A	-	-	0 N	-

PLUG WELDING

To weld ultra high strength steel of tensile strength 980 MPa or more, perform plug welding observing the welding hole diameter described in the manual.

CAUTION:

• To perform plug welding, use fuel mixture (Ar 80% + CO2 20%) for shielding gas of welder.

• Never use carbon dioxide gas (CO2 100%) as shielding gas of welder. Using CO2 100% gas results in inadequate weld strength.

• When welding hole diameter cannot be met, make multiple holes (smaller diameter) so that the sum of the hole areas equals the area of the original weld hole.

EXAMPLE

	Body sealing
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : N·m (kg-m, ft-lb) : For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to ″Welding of Ultra High Strength Steel″.

Side Radiator Core Support

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

: vehicle front : Weld the parts onto the back of the component part.
Replacement part
•	Side radiator core support

: vehicle front : Weld the parts onto the back of the component part.

Radiator Core Main Support

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

: vehicle front
Replacement part
•	Radiator core main support assembly

Hoodledge

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after side radiator core support is removed.

	Urethane foam		Body sealing
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. : N•m (kg-m, ft-lb)
Replacement part
•	Hoodledge assembly	•	Hoodledge reinforcement

	Urethane foam
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part.

PARTIAL REPLACEMENT

Work after side radiator core support is removed.

Unit: mm (in)
: vehicle front : N•m (kg-m, ft-lb)
Replacement part
•	Hoodledge assembly

View A: Before installing hoodledge connecter bracket assembly

Unit: mm (in)
: vehicle front : Weld the parts onto the back of the component part.

View D: Before installing hoodledge connecter bracket assembly

Front Pillar

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after hoodledge reinforcement and roof are removed.

	Body sealing		Urethane foam
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part.
Replacement part
•	Side body assembly	•	Side dash	•	Upper inner front pillar
•	Lower side dash assembly

	Body sealing
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel). : Drill φ12 mm (0.47 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. : N•m (kg-m, ft-lb)

View B: Before installing outer front side body

View E: Before installing outer front side body and front pillar brace

	Urethane foam
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Drill φ10 mm (0.39 in) hole for the plug welding hole (ultra high strength steel). : Drill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel). : N•m (kg-m, ft-lb) : N•m (kg-m, in-lb)

View H: Before installing outer front side body

PARTIAL REPLACEMENT

Work after hoodledge reinforcement is removed.

	Body sealing
Unit: mm (in)
: vehicle front : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part.
Replacement part
•	Side body assembly	•	Side dash	•	Lower side dash assembly

	Body sealing
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. : N•m (kg-m, ft-lb)

View B: Before installing outer front side body

View D: Before installing outer front side body and front pillar brace

	Body sealing
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Drill φ10 mm (0.39 in) hole for the plug welding hole (ultra high strength steel). : Drill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel). : N•m (kg-m, ft-lb) : N•m (kg-m, in-lb)

View G: Before installing outer front side body

Upper Dash

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after radiator core main support, side radiator core support, and hoodledge are removed.

: vehicle front : Weld the parts onto the back of the component part.
Replacement part
•	Upper dash assembly	•	Cowl top assembly

: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. : Welding method and the number of welding points apply to both sides of the vehicle.

Lower Dash

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after radiator core main support, side radiator core support, hoodledge, and upper dash are removed.

: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Welding method and the number of welding points apply to both sides of the vehicle.
Replacement part
•	Lower dash complete	•	Lower side dash assembly

	Adhesive
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. : N•m (kg-m, ft-lb) : Welding method, the number of welding points, and the tightening torque apply to both sides of the vehicle. : Adhesive portion apply to both sides of the vehicle.

View C: Before installing lower side dash assembly

Center Pillar

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

	Urethane foam
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). *: For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.
Replacement part
•	Outer front side body	•	Lower center pillar brace

	Urethane foam
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). *: For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.

View B, C, E, and G: Before installing outer front side body

Side Body

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after hoodledge reinforcement and roof are removed.

Remove the lower side dash assembly (reusable) from the vehicle for easier installation.

	Urethane foam
: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. *: For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.
Replacement part
•	Upper inner front pillar	•	Inner side roof rail	•	Inner center pillar
•	Side body assembly	•	Lower side dash assembly

	Body sealing
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel). : Drill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. : N•m (kg-m, ft-lb) : N•m (kg-m, in-lb)

	Body sealing
Unit: mm (in)
: vehicle front : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. *: For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel. : N•m (kg-m, ft-lb)

View H: Before installing lower side dash assembly

View J: Inner center pillar (replacement part) and side body assembly (replacement part)

	Urethane foam
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. : N•m (kg-m, in-lb)

Outer Sill

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

For easier installation, remove the "View A, B, C, D, E, F and U" weld point, bolt and nut.

Remove the lower side dash assembly (reusable) from the vehicle for easier installation.

	Body sealing		Urethane foam
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. *: For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel.
Replacement part
•	Outer sill assembly	•	Outer sill reinforcement

	Urethane foam		Body sealing		Lower side dash assembly (reusable)
: vehicle front : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. : N•m (kg-m, ft-lb)

View F: Before installing lower side dash assembly

View G: Before installing outer sill assembly

	Body sealing		Urethane foam		Lower center pillar brace (reusable)
Unit: mm (in)
: vehicle front : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).

View K and P: Before installing outer sill assembly

View N: Before installing outer sill assembly, lower center pillar brace, and outer sill reinforcement

View O: Before installing outer sill assembly and lower center pillar brace

	Urethane foam		Body sealing
Unit: mm (in)
: vehicle front : Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel). : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Drill φ10 mm (0.39 in) hole for the plug welding hole (ultra high strength steel). : Drill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part. *: For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to Welding of Ultra High Strength Steel. : N•m (kg-m, ft-lb) : N•m (kg-m, in-lb)

View R and T: Before installing outer sill assembly

PARTIAL REPLACEMENT

Unit: mm (in)
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
Replacement part
•	Outer sill assembly

Inner Center Pillar

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after center pillar and outer sill are removed.

Unit: mm (in)
: vehicle front
: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).
Replacement part
•	Inner center pillar

Inner Sill

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after lower side dash assembly, center pillar, outer sill, and inner center pillar are removed.

Unit: mm (in)
: vehicle front
: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ10 mm (0.39 in) hole for the plug welding hole (ultra high strength steel).
Replacement part
•	Inner sill

: vehicle front

: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).

: Weld the parts onto the back of the component part.

Front Floor

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after lower side dash assembly (LH), outer sill, and inner sill (LH) are removed.

Remove the lower side dash assembly (RH, reusable) from the vehicle for easier installation.

: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
Replacement part
•	Front floor assembly	•	2nd crossmember assembly (RH & LH)	•	Front floor reinforcement assembly
•	Rear floor front extension	•	Front side member assembly (RH & LH)	•	Front seat mounting rear crossmember assembly
•	4th crossmember assembly

	Lower side dash assembly (RH, reusable)		Adhesive
Unit: mm (in)
: vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ14 mm (0.55 in) hole for the plug welding hole (ultra high strength steel).
: Welding method and the number of welding points apply to both sides of the vehicle.
: N•m (kg-m, ft-lb)

View C and D: Before installing lower side dash assembly

	Adhesive
: vehicle front
: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ14 mm (0.55 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
: Welding method and the number of welding points apply to both sides of the vehicle.

: vehicle front

: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ10 mm (0.39 in) hole for the plug welding hole (ultra high strength steel).

: Weld the parts onto the back of the component part.

: Welding method and the number of welding points apply to both sides of the vehicle.

: vehicle front

: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).

: Weld the parts onto the back of the component part.

: Welding method and the number of welding points apply to both sides of the vehicle.

Rear Floor Front

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after rear fender, outer rear sill reinforcement, outer rear wheelhouse, and inner rear wheelhouse are removed.

Remove the welding point for easier installation.

: vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
: Welding method and the number of welding points apply to both sides of the vehicle.
Replacement part
•	Inner rear wheelhouse reinforcement assembly (RH & LH)	•	Rear floor front	•	3rd seat mounting bracket

: vehicle front

: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).

: Weld the parts onto the back of the component part.

: Welding method and the number of welding points apply to both sides of the vehicle.

Rear Seat Crossmember

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after rear fender, outer rear sill reinforcement, outer rear wheelhouse, inner rear wheelhouse, and rear floor front are removed.

Weld "view F" as shown in the illustration after installing the rear floor front.

Unit: mm (in)
: vehicle front
: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
Replacement part
•	Rear seat crossmember assembly

	Captain seat		Bench seat
: vehicle front
: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ10 mm (0.39 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.

: vehicle front

: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ10 mm (0.39 in) hole for the plug welding hole (ultra high strength steel).

: Weld the parts onto the back of the component part.

: Welding method and the number of welding points apply to both sides of the vehicle.

Rear Fender

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after roof is removed.

	Urethane foam		Body sealing
: Weld the parts onto the back of the component part.
Replacement part
•	Rear fender

	Body sealing
Unit: mm (in)
: vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
: N•m (kg-m, in-lb)

	Urethane foam
: vehicle front
: Weld the parts onto the back of the component part.
: N•m (kg-m, in-lb)

PARTIAL REPLACEMENT

	Urethane foam		Body sealing
: Weld the parts onto the back of the component part.
Replacement part
•	Rear fender

	Body sealing
Unit: mm (in)
: vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
: N•m (kg-m, in-lb)

Unit: mm (in)
: vehicle front
: Weld the parts onto the back of the component part.
: N•m (kg-m, in-lb)

View J: Before installing outer side body

Rear Fender Extension

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

	Body sealing
Unit: mm (in)
: Weld the parts onto the back of the component part.
Replacement part
•	Rear fender extension

Outer Rear Wheelhouse

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after rear fender is removed.

Remove the outer rear sill reinforcement (reusable) from the vehicle for easier installation.

	Outer rear sill reinforcement (reusable)
: vehicle front
Replacement part
•	Outer rear wheelhouse

	Outer rear sill reinforcement (reusable)		Body sealing
: vehicle front : Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel). : Weld the parts onto the back of the component part.

View C: Before installing outer rear sill reinforcement (reusable)

Inner Rear Wheelhouse

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

WITH DYNAMIC DIGITAL SUSPENSION AND ELECTRONIC AIR SUSPENSION MODELS

Work after rear fender, outer rear sill reinforcement, and outer rear wheelhouse are removed.

: vehicle front : Weld the parts onto the back of the component part.
Replacement part
•	Inner rear wheelhouse

Unit: mm (in)
: vehicle front : Weld the parts onto the back of the component part.

WITHOUT DYNAMIC DIGITAL SUSPENSION AND ELECTRONIC AIR SUSPENSION MODELS

Work after rear fender, outer rear sill reinforcement, and outer rear wheelhouse are removed.

: vehicle front : Weld the parts onto the back of the component part.
Replacement part
•	Inner rear wheelhouse

Unit: mm (in)
: vehicle front : Weld the parts onto the back of the component part.

Inner Rear Pillar Reinforcement

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after rear fender is removed.

	Urethane foam
Unit: mm (in)
: vehicle front : Weld the parts onto the back of the component part.
Replacement part
•	Inner rear pillar reinforcement

Inner Rear Pillar

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after rear fender, inner rear pillar reinforcement, and back pillar reinforcement are removed.

Remove the welding point for easier installation.

	Urethane foam
: vehicle front : Weld the parts onto the back of the component part.
Replacement part
•	Inner rear pillar	•	Inner back pillar	•	Inner rear side roof rail
•	Lower inner rear pillar

Unit: mm (in)
: vehicle front : Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel). : N•m (kg-m, in-lb)

	Urethane foam
: vehicle front
: N•m (kg-m, in-lb)

Back Pillar Reinforcement

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Work after rear fender is removed.

	Urethane foam
Unit: mm (in)
: vehicle front
Replacement part
•	Back pillar reinforcement

	Urethane foam
: vehicle front
: N•m (kg-m, in-lb)

Rear Panel

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

: vehicle front
: Weld the parts onto the back of the component part.
: Welding method, the number of welding points, and the tightening torque apply to both sides of the vehicle.
: N•m (kg-m, in-lb)
Replacement part
•	Rear end crossmember assembly

Rear End Crossmember

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

	Urethane foam
Unit: mm (in)
: vehicle front
: Welding method, the number of welding points, and the distance in the figure apply to both sides of the vehicle.
: Urethane foam portion apply to both sides of the vehicle.
Replacement part
•	Rear end crossmember assembly	•	Rear crossmember assembly

	Urethane foam
Unit: mm (in)
: vehicle front
: Weld the parts onto the back of the component part.
: Welding method, the number of welding points, the distance in the figure, and the tightening torque apply to both sides of the vehicle.
: Urethane foam portion apply to both sides of the vehicle.
: N·m (kg-m, in-lb)

: vehicle front

: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).

: Welding method, the number of welding points, and the tightening torque apply to both sides of the vehicle.

: N•m (kg-m, ft-lb)

Rear Floor Rear

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

WITH ProPILOT Assist 2.1 MODELS

Work after rear end crossmember is removed.

: vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
: Welding method and the number of welding points apply to both sides of the vehicle.
Replacement part
•	Rear floor rear	•	Rear side member	•	3rd rear crossmember assembly

: vehicle front

: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel).

: Welding method and the number of welding points apply to both sides of the vehicle.

WITHOUT ProPILOT Assist 2.1 MODELS

Work after rear end crossmember is removed.

: vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
: Welding method and the number of welding points apply to both sides of the vehicle.
Replacement part
•	Rear floor rear	•	Rear side member	•	3rd rear crossmember assembly

: vehicle front

: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).

: Drill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel).

: Welding method and the number of welding points apply to both sides of the vehicle.

Roof

WITHOUT SUNROOF MODELS

	3M™ Urethane Seam Sealer 08368 or equivalent
: vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
: Welding method and the number of welding points apply to both sides of the vehicle.
Replacement part
•	Roof	•	Roof bow	•	2nd roof bow
•	3rd roof bow	•	4th roof bow	•	5th roof bow

	Adhesive
: vehicle front
: Weld the parts onto the back of the component part.
: Welding method, the number of welding points, and the tightening torque apply to both sides of the vehicle.
: Adhesive portion apply to both sides of the vehicle.
: N·m (kg-m, in-lb)

WITH SUNROOF MODELS

	3M™ Urethane Seam Sealer 08368 or equivalent		Adhesive
: vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
: Welding method, the number of welding points, and the tightening torque apply to both sides of the vehicle.
: Adhesive portion apply to both sides of the vehicle.
: N·m (kg-m, in-lb)
Replacement part
•	Roof assembly	•	4th roof bow

Roof Rail

Work after roof is removed.

: vehicle front
: Drill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel).
: Drill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel).
: Weld the parts onto the back of the component part.
: Welding method, the number of welding points, and the tightening torque apply to both sides of the vehicle.
: N•m (kg-m, in-lb)
Replacement part
•	Front roof rail	•	Rear roof rail

Crush Horn

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Unit: mm (in)
: vehicle front
Replacement part
•	Front side member assembly	•	1st cab mounting bracket assembly	•	Front side member closing assembly (Front)

Rear Frame

WARNING:

• Jacking up or lift up the vehicle may the vehicle height to go down which cause a personal injury and/or damage to the air suspension component parts. Refer to Precaution for when Jacking and Lifting Up the vehicle with Electronic Air Suspension System.

Unit: mm (in)
: vehicle front
Replacement part
•	Rear end crossmember assembly	•	Rear end gusset	•	Rear side member assembly (LH)
•	5th cab mounting bracket (LH)

View B: Before installing inner rear side member

Unit: mm (in)
: vehicle front
: Welding method and the distance in the figure apply to both sides of the vehicle.

View C: Before installing inner rear side member

View D: Before installing inner rear side member, outer rear side member, and 5th cab mounting bracket (LH)