TM 55-8145-202-14
4-22.
REAR DOORS.
This task covers:
a. Repair
b. Removal
c. Installation
INITIAL SET-UP:
Tools:
Materials/Parts:
General Mechanics Tool Kit (Item 1, App B)
Rivet (Item 16, App E)
Automotive Vehicle Shop Set (Item 2, App B)
Adhesive (A/R) (Item 1, App E)
Wiping rag (Item 6, App E)
Equipment Condition:
Foam (Item 4, App E)
Refrigeration unit shutdown (TM 9-4110-258-13)
Barrier Tape (Item 3, App E)
Generator set shutdown (TM 5-6115-585-12/34)
Sealant (Item 8, App E)
Detergent (Item 2, App E)
NOTE
Repair to the right door is shown, left door repair is similar.
Exterior door panel repairs have the following limitations:
No welding of aluminum patches.
If a patch would cover more than 75% of door panel, replace the entire door.
If damage extends to within 2 inches (50 mm) of the edge of the panel, the overlay patch
must extend to the panel edge Use original fastener holes and original overlapping
pattern.
NOTE
Replacement panels and patches must be made from aluminum material of the same
thickness and specification as the damaged panel. Use prepainted patches when
appropriate.
Wet or damaged foam must be replaced before patching or installing a replacement
panel.
Aluminum patches should be cleaned and coated with adhesive primer before
application. The part of panel to be overlapped by the patch must also be cleaned and
coated with adhesive primer before the patch is applied.
Patches must adhere to the underlying foam with solvent-free polyurethane adhesive.
Patches must be properly riveted to the remaining panel.
Rivets must be of a weather-resistant type.
Minimum rivet diameter is 3/16 inch (4.5 mm).
4-26
