10-11. CARGO BODY PICKUP BOX MAINTENANCE (Cont).
b.1 . PREPARATION OF SIDE PANEL (M1028A2 AND M1028A3)
If body side panel is damaged and must be replaced, side panel must be
cut using modification template to accept rear fender.
This task requires use of template to modify side panel. (See
Cut out fender template along cut lines.
Crease template on body crease line for ease of alinement.
Aline template fore and aft gage line with hole for fender brace located at front of wheel opening
on side panel.
Aline front section of template vertically, using body crease line,
Tape front section of template securely to side panel. Continue taping template to side panel
keeping front section alined on body crease line.
After taping template, check that fore and aft gage
Mark fender cut line with scribe or suitable marker.
line is still in line with fender hole.
There are 26 hole locations per side panel,
Center punch all hole locations marked A, B, C, and D.
Using template as reference, cut 2 holes at location A with 11/8 in. (28.58 mm) hole saw, for
installation of electrical harness and grommets.
Drill 19 holes marked B with ¼ in (6.35 mm) drill bit, as pilot holes
Drill 19 pilot holes prepared in step 10 with 29/64 in. (1 1.50 mm) drill bit for installation of fender
and inner filler panel.
Drill 2 holes at location C with 9/32 in. (7.14 mm) drill bit, for installation of harness shields.
Drill 3 holes marked D with 1/4 in (6.35 mm) drill bit, for installation of wiring harness retainers.
Mark inner side panel for cutting approximately 1 1/2 in. (38.10 mm) out from vertical bend of inner
edge (approximately at base of radius).
10-42 Change 2