TJ rear passenger corner panel removal

[Gropoto]

Good evening to all jeepers! Hope I can get an idea on how to tackle the the removal and replacement of my TJ rear passenger corner panel, just the corner. I recently got struck and that panel there is sheared off along the rear bumper crown. Any input will be gratefully appreciated.
Thanks!

 

[reddvltj]

Good evening to all jeepers! Hope I can get an idea on how to tackle the the removal and replacement of my TJ rear passenger corner panel, just the corner. I recently got struck and that panel there is sheared off along the rear bumper crown. Any input will be gratefully appreciated.
Thanks!

First you need a new panel.

https://www.extremeterrain.com/jeep...qcg6IzhADQWn_Mp6r4BoCp_kQAvD_BwE&gclsrc=aw.ds


This might not be exactly what you are after but it might help you get an idea of what you are up against.

 

[Gropoto]

First you need a new panel.

https://www.extremeterrain.com/jeep...qcg6IzhADQWn_Mp6r4BoCp_kQAvD_BwE&gclsrc=aw.ds


This might not be exactly what you are after but it might help you get an idea of what you are up against.

Thanks

First you need a new panel.

https://www.extremeterrain.com/jeep...qcg6IzhADQWn_Mp6r4BoCp_kQAvD_BwE&gclsrc=aw.ds


This might not be exactly what you are after but it might help you get an idea of what you are up against.

Thanks,

First you need a new panel.

https://www.extremeterrain.com/jeep...qcg6IzhADQWn_Mp6r4BoCp_kQAvD_BwE&gclsrc=aw.ds


This might not be exactly what you are after but it might help you get an idea of what you are up against.

Thanks much for the reply. I must admit, I had watched this video before and see the tremendous difficulties about the task but remain hopeful that someone in the forum had handled it in an easier manner.
Thanks!

 

[TJ4Jim]

Don't know about that video, seems like they made a huge process out of it with all the additional cutting and bending.. I used a small pneumatic angle grinder with disc's to expose the spot welds and bought a few Fostner type spot weld cutters off of Amazon. I found it fairly simple to over drill the welds and the corner was off in about 45 minutes. New corner fit in and tacked up without real issues but the seam sealer was a bit messy to deal with.

 

[Gropoto]

Thanks Tj4jim,
I’m just not sure understanding the pictures

 

[reddvltj]

Thanks


Thanks,


Thanks much for the reply. I must admit, I had watched this video before and see the tremendous difficulties about the task but remain hopeful that someone in the forum had handled it in an easier manner.
Thanks!

Hs methods were definitely crude but you get a sense of what it's going to take (aside from all his extra cutting and bending).

 

[reddvltj]

Thanks Tj4jim,
I’m just not sure understanding the pictures

View attachment 483510

View attachment 483512

His pictures are of the underlying structure once the rear corner panels are removed. All the little dots are spot welds that he had to drill to remove the old corner panel.

After looking at the picture of your damage, you're going to need to do more than just remove and replace the rear corner. You're going to have to straighten the fender panel (part of the tub itself) also.

 

[PurpleTJAZ]

Thanks Tj4jim,
I’m just not sure understanding the pictures

View attachment 483510

View attachment 483512

You are going to be into two body panels and at least two probably three inner structures. It looks superficial but it’s not. @reddlvtj has pictured the correct way to separate the panels. There is really no easy way to do this repair. It looks like you also took the brunt of the impact in the axle area. Have you investigated whether the housing is bent? That may end up being a more pressing concern.

 

[97JadeTJ]

I was rear-ended a couple months ago with similar damage to you…

I chose a different route of repair… Body Armor!

I hammered the dent out as much as I needed so that the armor would fit flat on it and rattle canned the sections that the paint chipped off and then bolted the panels on… No further bodywork needed… It’s a lot heavier now than it was!

 

[Moglocker]

I was rear-ended a couple months ago with similar damage to you…

View attachment 483522

I chose a different route of repair…
View attachment 483523

View attachment 483524

I hammered the dent out as much as I needed so that the steel panel would fit flat on it and rattle canned the sections that the paint chipped off and then bolted the panels on… No further bodywork needed… It’s a lot heavier now than it was!

This is how I would do it,looks GREAT but those license plates are made of heavy metal and are hard to bend flat (lol)j/k did you get any funds from the guy that hit you?

 

[JMT]

Thanks Tj4jim,
I’m just not sure understanding the pictures

View attachment 483510

View attachment 483512

My sons TJR had a bad corner panel and we chose to put armor over it. For weight savings go with Aluminum. For steel you can use a half corner armor to save a bit of weight. Body match either way. Or figure out the panel work. Your choice! Pretty Jeep.

 

[Moglocker]

My sons TJR had a bad corner panel and we chose to put armor over it. For weight savings go with Aluminum. For steel you can use a half corner armor to save a bit of weight. Body match either way. Or figure out the panel work. Your choice! Pretty Jeep.

Get a new flare and you can get an aluminum warrior corner and paint match,dunzzo!

 

[97JadeTJ]

This is how I would do it,looks GREAT but those license plates are made of heavy metal and are hard to bend flat (lol)j/k did you get any funds from the guy that hit you?

I’ve already gotten a new license plate to replace the damaged one… OCD made me!…

I have full coverage insurance and it was a hit and run so my insurance paid…

 

[Gropoto]

You are going to be into two body panels and at least two probably three inner structures. It looks superficial but it’s not. @reddlvtj has pictured the correct way to separate the panels. There is really no easy way to do this repair. It looks like you also took the brunt of the impact in the axle area. Have you investigated whether the housing is bent? That may end up being a more pressing concern.

You are going to be into two body panels and at least two probably three inner structures. It looks superficial but it’s not. @reddlvtj has pictured the correct way to separate the panels. There is really no easy way to do this repair. It looks like you also took the brunt of the impact in the axle area. Have you investigated whether the housing is bent? That may end up being a more pressing concern.

You are going to be into two body panels and at least two probably three inner structures. It looks superficial but it’s not. @reddlvtj has pictured the correct way to separate the panels. There is really no easy way to do this repair. It looks like you also took the brunt of the impact in the axle area. Have you investigated whether the housing is bent? That may end up being a more pressing concern.

Thanks PurpleTjaz, great infos. Yes I took a hit on the rear end of the 35in tire to rip out of the jeep breaking the axel shaft at the outer tip of the bearing and the seal. That tip is slightly bent about a little over a 1/4 in towards the rear. I am hoping to be an able to get by replacing the shaft axle with the least difficulty.

 

[PurpleTJAZ]

Wow that really sucks. I have seen hard hits like that actually bend the axle housing tube. The backing plate, brakes and axle are the easier part. If that axle tube bent it will just eat axle seals and bearings as fast as you replace them. There can also be damage to the spider bearing inside the differential.
I'm not trying to crap you out, its just that I have traveled the road you are headed down before. I encourage you to inspect and know where you are at with your axle and suspension before you get too worried about body work. A jeep with body damage going down the road is ugly but a good looking jeep with a broken axle is yard art. Good luck I hope the damage is minimal.
Oh and by the way that's a great looking TJ.

 

[Gropoto]

Wow that really sucks. I have seen hard hits like that actually bend the axle housing tube. The backing plate, brakes and axle are the easier part. If that axle tube bent it will just eat axle seals and bearings as fast as you replace them. There can also be damage to the spider bearing inside the differential.
I'm not trying to crap you out, its just that I have traveled the road you are headed down before. I encourage you to inspect and know where you are at with your axle and suspension before you get too worried about body work. A jeep with body damage going down the road is ugly but a good looking jeep with a broken axle is yard art. Good luck I hope the damage is minimal.
Oh and by the way that's a great looking TJ.

Thank you again, I’ll look and inquire a little deeper. By the way there’s no way to partially replace the shaft outer housing or is there?

 

[PurpleTJAZ]

Thank you again, I’ll look and inquire a little deeper. By the way there’s no way to partially replace the shaft outer housing or is there?

No.
Looks like it has a Dana 35 so you have to pull the differential cover and then the spider gears to get the axle clips loose to slide the axle shaft out.

 

[TJ4Jim]

Thank you again, I’ll look and inquire a little deeper. By the way there’s no way to partially replace the shaft outer housing or is there?

The Dana 35 axles are commonly available used and really not worth repairing.

 

[Gropoto]

No.
Looks like it has a Dana 35 so you have to pull the differential cover and then the spider gears to get the axle clips loose to slide the axle shaft out.

Yes it is a Dana 35 and that is the plan of a plan of approach . The diff and axel seem to be a one piece, cannot be separated.

 

[PurpleTJAZ]

Yes it is a Dana 35 and that is the plan of a plan of approach . The diff and axel seem to be a one piece, cannot be separated.

You will need to disassemble it to get it apart.