TM 9-2320-363-34-2
To facilitate repairs to body, it is acceptable to replace took bolts and rivets with 1/4-in. AN4 series
bolts. Do not replace lock bolts with rivets. Standard threaded fasteners should not be used as these will
quickly wear the aluminum structure. Bolt lengths should be chosen so that the cylindrical portion of the bolt
is bearing on all members being joined. Bolts are designated as AN4-XX or AN4C-XX, where XX defines
grip length. Tighten all bolts to 70-75 lb-in. (8 N.m).
All riveted joints have adhesive foam between both components riveted together. The purpose of this
tape is to ensure watertight joints and to ensure aluminum components will not wear prematurely. Tape may
-
be either 1 in. or 2 in. wide depending on
during disassembly. The only time adhesive
taken apart.
the joint. Replace adhesive tape with the same size removed
foam tape is to be replaced is if a riveted joint is completely
General
The damaged area should be thoroughly cleaned and inspected to determine cause and extent of
damage. Body parts should be inspected for holes, cracks, dents, distortion, or breaks. Fasteners should be
inspected for breaks, stretching, looseness, cocked heads, or hole elongation. Seams, flanges, and joints
should be inspected for straightness or local deformation as an indication that fasteners may have been
stretched or holes elongated. It is possible for this to happen and for fasteners to still appear to be tight in
their holes. In addition, make a thorough inspection of adjacent areas to determine if high loads have been
transmitted from the damaged area to other areas. This can result in secondary damage in the form of
distorted panels or seams, loosened or sheared fasteners, elongated fastener holes, and cracks.
Classification
After extent of damage has been determined, affected parts should be classified in one of the following
categories:
Negligible Damage
Damage Repairable By Patching
Damage Repairable By Insertion
Damage Necessitating Replacement Of Parts
1.
Negligible Damage. Minor dents, nicks, scores, cracks, and holes in body panels which are within or
are brought within reasonable limits by a simple procedure without extensive rework. These defects
should be considered more serious if located in main structural members such as body side rails, a
pillars, or floor crossmembers rather than in body panels such as cowls or rear wheelhouses. Deep
wrinkles of undetermined origin in body panels should not be classed as negligible until the source of
wrinkles has been investigated and positively identified. damage other than small dents, holes, nicks,
and scratches will require repair or replacement of the part. Refer to repair of negligible damage,
below.
Negligible Cracks. Isolated cracks less than 0.50 in. (1.27 cm) long may be classified as
negligible cracks provided they are stop drilled at each end to stop propagation.
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