Defender (1999-2002). Manual — part 106
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PANEL REPAIRS
11
BODY DIMENSIONS
Section K-K, Roof to taildoor, gap K = 7 - 9 mm. Profile = +/- 1 mm.
Section L-L, N-N, Body side to taildoor, gap L = 5 - 7 mm. Profile = +/- 1 mm.
Section M-M, Body rear to taildoor, gap M = 7 - 9 mm.
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PANEL REPAIRS
1
SEALING AND CORROSION PROTECTION
APPROVED MATERIALS
Joint types:
1. Between bolted panels
2. Between bolted panel edges
3. Between spot welded panels
4. Between spot welded panel edges
5. Between bonded panels
6. Between bonded panel edges
7. Clinch joints (type a)
8. Clinch joints (type b)
9. Clinch joints (type c)
10. Gaps between panels (type a)
11. Gaps between panels (type b)
12. Lap joint
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77
PANEL REPAIRS
2
SEALING AND CORROSION PROTECTION
DESCRIPTION - USEAGE
SUPPLIER
PART NUMBER
CAVITY WAXES
Inner Cavity Wax (Transparent)
3M
(08909, 08919,
08929)
Inner Cavity Wax (Amber)
3M
(08901, 08911,
08921)
Cavity Wax
Croda
(PW57)
ENGINE BAY WAXES/LACQUERS
Astrolan engine bay wax and Cosmetic Wax
Astors
DA3243/1
Engine Bay Cosmetic Wax/Lacquer
Croda
PW197
Engine Bay Cosmetic Wax/Lacquer
Dinol
4010
MISCELLANEOUS MATERIALS
Flexible Parts Repair Material - rubber modified
polypropylene parts
3M:
(05900)
Aerosol Auto’ Adhesive (trim) - impact adhesive for trim parts 3M
(08080)
Water Shedder Repair
Teroson:
Sound dampening foam
Gurit Essex:
Betacore 7999
SEAM SEALERS
Body Caulking - type (b) gaps between panels
3M
08568
Drip Chek Clear - bolted, spot welded and bonded panel
edges; type (a) and (b), gaps between panels; type (c) clinch
joints
3M
08401
Drip Chek Heavy - type (b) gaps between panels; type (c)
clinch joints
3M
08531
Flexseal Polyurethane Seam Sealer - bolted, spot welded
and bonded panel edges; type (a) and (b) gaps between
panels; type (b) clinch joints
3M
(08684, 08689,
08694)
Polyurethane Sealer (sachet)
3M
(08703, 08783,
08788)
Sprayable Sealer - type 12 lap joints
3M
(08800, 08823)
Super Seam Sealer - type 12 lap joints
3M
(08537)
Weld Thru’ Sealer - between spot welded panels
3M
(08625)
Betafill Clinch and Brushable Sealer (Black, Grey, White)
Gurit Essex
10211/15/20
Clinch Joint and Underbody Coating (Grey, Beige)
Gurit Essex
(10101, 10707)
Leak-Chek Clear - between bolted panels; spot welded and
bonded panel edges; type (c) clinch joints
Kent Industries
(10075)
Putty - type (a) and (b) gaps between panels
Kent Industries
Polyurethane Seam Sealer between bolted panels; spot
welded and bonded panel edges; type (a) and (b) gaps
between panels
PPG
(6500)
Polyurethane Seam Sealer between bolted panels; spot
welded and bonded panel edges; type (a) and (b) gaps
between panels
Teroson
92
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PANEL REPAIRS
3
SEALING AND CORROSION PROTECTION
DESCRIPTION - USEAGE
SUPPLIER
PART NUMBER
SEAM SEALERS - continued
Terolan Light Seam Sealer - bolted, spot welded and bonded
panel edges; type (a) and (b) gaps between panels; between
bonded panels; type (c) clinch joints
Teroson
Terolan Special Brushable Seam Sealer - lap joints 12
Teroson
Terostat Sprayable Seam Sealer - bolted, spot welded and
bonded panel edges; between bonded panels; type (a) and
(b) gaps between panels
Teroson
9320
Terostat 1K PU Seam Sealer (SE 20) - type (a) and (b) gaps
between panels; spot welded and bonded panel edges
Teroson
Sealing compound - bolted, spot welded and bonded panel
edges; type (b) gaps between panels
Wurths
8901001/-/6
STRUCTURAL ADHESIVES
Automotive Structural Adhesive - between bonded panels;
type 5 and 7
3M
08122
Two part Structural Epoxy - between bonded and spot
welded panels; type (a) clinch joints
Ciba - Geigy
XB5106/7
UNDERBODY SEALERS
Body Schutz
3M
08861
Spray Schutz
3M
08877
Crodapol Brushable Sealer
Croda
PV75
Terotex Underseal (CP02)
Teroson
9320
UNDERBODY WAXES
Stone chip coating (smooth)
3M
08158/9
Underbody Wax
Croda
PW61
Underbody Wax
Dinol
Tectacote 205
WELD-THROUGH PRIMERS
Weld-thru’ coating
3M
05913
Zinc Spray
3M
09113
Zinc Rich Primer
ICI
P-565 634
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