NUMBER: 23-026-02
GROUP: Body
DATE: Jun. 10, 2002
This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.
THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR
PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL JUNE 30, 2002.
SUBJECT:
Floor Pan Corrosion
OVERVIEW:
This bulletin involves the removal of corrosion perforation and the installation of new floor pans
MODELS:
1984 - 2001 XJ Cherokee
SYMPTOM/CONDITION:
The vehicle may demonstrate floor pan corrosion perforation caused by: water/salt water
intrusion into the interior of the vehicle. Mud collecting on the underbody surfaces of
the floor pan that retains road salt and moisture. Holes being drilled through the floor
pan for accessories without applying the proper corrosion resistant coatings.
DIAGNOSIS:
1. Using the appropriate year Service Manual and Section 0, place the vehicle on a hoist.
2. Inspect the underside of the floor pan for corrosion perforation; if there is corrosion
perforation in the floor and the frame rails are intact proceed with the repair.
PARTS REQUIRED:
Left side, pre 94 (without front seat risers)
Qty Part No. Description
1 05072501AA Lt. Side 1/2 front floor pan
1 05093241AA Inner seat mounting bracket
1 Kit 05093204AA XJ floor pan installation kit
Right side, pre 94 (without front seat risers)
Qty Part No. Description
1 05072502AA Rt. Side 1/2 front floor pan
1 55235811AB Muffler shield + hardware
1 05093240AA Inner seat mounting bracket
1 Kit 05093204AA XJ floor pan installation kit
23-026-02 -2-
Right side, post 94 (with front seat risers)
Qty Part No. Description
1 05072514AA Rt. Side 1/2 front floor pan
1 05093242AA Inner seat mountintg bracket
1 55235811AB Muffler shield + hardware
1 Kit 05093204AA XJ floor pan installation kit
Left side, post 94 (with front seat risers)
Qty Part No. Description
1 05072515AA Lt.Side 1/2 front floor pan
1 05093243AA Inner seat mounting bracket
1 05093204AA Floor pan kit, Lt. side with seat riser
EQUIPMENT/MATERIALS REQUIRED:
Qty Description
1 Drill motor W-7804R (PSE)
2 cartridges per side MOPAR Structural Adhesive 05083855AA
1 MOPAR Adhesive gun 05016570AA
1 17/64" Drill bit
1 Spot weld cutter - 7/16 Rotabroach cutter 11112
and Arbor 11089. For information call 586-677-1277
or
[email protected]
1 Pneumatic rivet gun W-AK175ACH
1 Air hammer (PSE)
1 Scraper
1 Heat gun W-PH 1200 Varitemp (PSE)
1 Scotch-Brite™ Roloc™ + Clean and Strip XT
Disc + Holder 07470
REPAIR PROCEDURES:
See following notes.
NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION
SHEET INCLUDED IN THE PARTS KITS.
NOTE: THERE MAY BE MARKETS OUTSIDE THE U.S. WHERE LOCAL
RESTRICTIONS DO NOT ALLOW STRUCTURAL ADHESIVE REPAIRS AS
RECOMMENDED IN THE INSTRUCTION SHEET IN THE TSB. FOR THOSE
MARKETS AN ALTERNATIVE WELD REPAIR PROCESS IS AVAILABLE THROUGH
YOUR COUNTRY OFFICE TECHNICAL SUPPORT TEAM.
-3- 23-026-02
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: Description Amount
23-85-80-92 Floor pan repair-Left or Right (1 side) 12.0 Hrs.
23-85-80-93 Floor pan repair-Left and Right
(both sides
20.0 Hrs.
FAILURE CODE:
P1 Rust Perforation