How to install, repair or replace a metal deck lid - By: Ilie

This procedure describes the repair, replacement, and inspection of a plastic deck lid. Adhesive repairs are included for all types of thermoset plastics.
The purpose of this procedure is to provide industry-accepted requirements for performing high-quality repair of plastic deck lids. This procedure is intended for use by professionals who are qualified through training and experience.

Equipment: The use of a hinge-pin removal tool is included in this procedure. Use plastic adhesive.

Damage Analysis

Inspect a plastic deck lid assembly for these conditions:
visible damage
improper previous repairs
misalignment with adjacent panels
reinforcements that have separated from the deck lid
damaged or missing trim, labels, seals, etc.
missing or damaged anti-flutter materials
damaged latch or lock cylinder
damaged hinges, torsion rods, or struts
damaged lamp or reflector assembly
Determine whether the deck lid is to be repaired or replaced. Verify the availability of replacement parts. If there is severe damage to the hinge or striker mounting areas, the deck lid should be replaced.

Deck Lid Repair Safety

Make sure the deck lid is properly supported, and use proper lifting techniques during removal and installation.
Torsion rods and spring-loaded hinges are under tension. Use special caution when working on deck lids equipped with torsion rods or spring-loaded hinges.

Vehicle Protection
Deck Lid And Adjacent Areas
When working with a plastic deck lid:
Protect the deck lid to prevent further damage during the repair.
Protect adjacent panels and glass from damage.

[Repair procedure of plastic decklids]
Deck Lid Repair

To repair a plastic deck lid:

1. Remove interior and exterior trim parts, if required for access.
2. Perform repairs using plastic adhesive repair procedures.
3. Replace trim-mounting studs or holes, if required.
4. Apply primer to all interior and exterior surfaces damaged by the collision or repairs.
5. Check the deck lid alignment. Adjust if required.
6. Refinish the deck lid to restore the appearance, including edges damaged by the collision or repairs. Refinish cosmetic surfaces after all body repairs are complete.
7. Replace or restore sound deadeners and anti-flutter materials that were damaged by the collision or repair
8. Install the inner trim panel.
9. Replace all trim, labels, weatherstrips, etc.
10. Continue vehicle reassembly.

Deck Lid Removal

1. Open and support the deck lid.
2. Protect the backlite and adjacent panels.
3. Disconnect the electrical connectors, cables, hoses, and torsion rods, if required
4. Mark the hinge positions on the deck lid, and on the body panel if the hinges are being replaced. Use existing painted surfaces as a reference.
5. Unfasten the deck lid from the hinges. Note the location of any a vehicle. shims.
6. Carefully remove the deck lid from the vehicle.
7. Remove the striker assembly.

Deck Lid Installation
1. If installing a replacement deck lid, refinish the underside and edges of the deck lid before installation.
2. Protect the backlite and adjacent panels.
3. Support the deck lid on the hinges, and loosely install the fasteners. Reinstall any removed shims.
4. Lower the deck lid slowly. Make sure it does not contact the adjacent panels.
5. Check for proper alignment to the adjacent panels. Adjust the position at the hinges as needed.
6. Raise the deck lid and properly torque all fasteners to the vehicle maker ’s recommendations.
7. Close the deck lid and recheck the alignment.
8. Install the striker assembly.
9. Lower the deck lid slowly to see if the striker properly enters the latch assembly without forcing the deck lid out of alignment. Align the latch assembly, or the striker as needed.
10. Reconnect the torsion rods, electrical connectors, cables, and hoses.
11. Spot paint the hinges and fasteners, if required.
12. Refinish the deck lid after all body repairs are complete.
13. Transfer or install replacement parts such as handles, lock cylinders, latch assemblies, etc.
14. Install trim, labels, weatherstrips, seals, etc.
15. Lubricate the hinges and latch, if required. Follow the vehiclemaker ’s recommendations.
16. Test all electrical accessories for proper operation.
17. Perform water leak tests to ensure proper sealing.
18. Continue vehicle reassembly.

Use Of Recycled (Salvage) Parts

Condition Of Salvage Parts

Do not install a salvage plastic deck lid having any of these defects:
unrepairable damage
damage caused by fire
improper previous repairs
reinforcements that have separated from the deck lid

Replace any damaged or missing trim, labels, seals, latches, etc. Confirm that labels or information decals match the original. Replace if required.

[Plastic decklid inspection and testing]
Inspection And Testing

Inspection Of A Repaired Or Replaced Plastic Deck Lid

After installation or repair, inspect a steel deck lid for these conditions:
proper alignment with adjacent panels
fasteners torqued to the vehicle maker’s recommendations
proper application of anti-flutter materi
proper operation of the lock cylinder
proper operation of the torsion rods
proper lubrication of the hinges, latch, and lock cylinder
proper latching and release
proper finish appearance and film thickness
proper installation of all trim, labels, and fasteners
proper installation of hoses, cables, wiring, and electrical connectors
proper operation of electrical accessories
proper sealing against air and water leaks

About the Author

For more informations about decklids, how to install, how to repair or replace a deck lid visit: Decklids

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