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Improvement Team
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CAR M310330 ASSEMBLY
Front End Assembly Cell
21125557
RH FRAME
EXTENSION
21125555
LH FRAME
EXTENSION
27QL299M
(25176484)
TOW HOOK
RIGHT HAND
27QL299M2
(25176483)
TOW HOOK
LEFT HAND
STEP #1 - PLACE THE LEFT AND
RIGHT HAND FRAME EXTENSIONS
ONTO THE FIXTURE ON THEIR SIDE
AS SHOWN IN DIAGRAM 1. STEP #2 - INSERT THE INDICATED
TOW HOOK INTO EACH SIDE.
PLACE THESE WITH THE HUCK
SPIN BOLTS ALREADY IN PLACE, INTO
THE HOLES IN EACH FRAME
EXTENSION. (4AM23 IS A LONGER
HUCK SPIN BOLT AND IS PLACED
CLOSEST TO THE CURVE IN THE
HOOK. THE UPPER HUCK SPIN BOLT
IS 4AM22) REFER TO DIAGRAM 2
4AM22
(25164087)
HUCK SPIN
BOLT 4AM23
(25166332)
HUCK SPIN
BOLT
DIAGRAM 2
DIAGRAM 1
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159AM3
HUCKSPIN COLLAR
STEP #3 - PLACE 1 HUCK SPIN COLLAR (159AM3) ON EACH HUCK
SPIN BOLT THREADED THROUGH THE TOW HOOKS
(REF - DIAGRAM 3)
STEP#4 - TIGHTEN ALL 4 HUCK SPIN COLLARS USING
THE HUCK BOLT GUN.
DIAGRAM 3
159AM3
HUCKSPIN COLLAR
CAR M310330 ASSEMBLY
2
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CRITICAL COMPONENT 21125482 FRAME EXTENSION FRONT
STEP #5 - STAND THE FRAME EXTENSION
21125557 UP, AND PLACE ON THE LOCATING
PINS OF THE FIXTURE. STEP #6 - FIT THE FRONT FRAME EXTENSION
(21125482) INTO PLACE WITH THE RH FRAME
EXTENSION (21125557) (REF. DIAGRAM 4) STEP #7 FIT THE FRONT FRAME EXTENSION
(21125482) INTO PLACE ON THE LH FRAME
EXTENSION (21125555) STEP #8 PLACE LH FRAME EXTENSION ONTO
THE LOCATING PINS ON THE FIXTURE.
DIAGRAM 4
CAR M310330 ASSEMBLY
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CRITICAL COMPONENT 21125482 FRAME EXTENSION FRONT. RED light normally ON. If
missing component, RED light will remain ON and air is shut-off.
POKE YOKE CHECK --> IF
COMPONENT IS NOT PRESENT, CANNOT
TORQUE THE BOLTS (SHUT-OFF VALVE)
4
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Lift the Front End Extension and place it on the spacer bar to assist with assembly of the LH
side. The spacebar activates the sensor and rhe light turns GREEN
5
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ASSEMBLED FRONT END EXTENSION
6
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20904633
FRAME
EXTENSION
FRONT
DIAGRAM 5
STEP #9 FIT THE OTHER FRONT FRAME EXTENSION (20904633)
INTO PLACE ON TOP. (REF. DIAGRAM 5)
CAR M310330 ASSEMBLY
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STEP #10 INSERT THE SPACER BAR ONTO THE ASSEMBLY AS SHOWN ABOVE
TO STABALIZE THE PART.
RELIABLE METHOD: HOLES ON THE SPACER BAR
MUST LINE UP WITH THE HOLES ON THE FRAME
EXTENSIONS.
CAR M310330 ASSEMBLY
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STEP #11 INSERT 1 FLANGE SCREW (27AM99) PER SIDE THROUGH THE
INDICATED HOLE IN 21125482 AND EACH FRAME EXTENSION. STEP #12 SECURE EACH FLANGE SCREW BY HAND USING 1 FLANGE
LOCK NUT EACH.(191AM13)
CAR M310330 ASSEMBLY
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VIEW FROM
BACKSIDE
OF ASSEMBLY
STEP #13 INSERT 2 FLANGE SCREWS (27AM99) PER SIDE
THROUGH THE FRONT FRAME EXTENSION AND THE LH AND
RH FRAME EXTENSIONS. STEP #14 SECURE THESE 4 FLANGE SCREWS BY HAND
USING 1 FLANGE LOCK NUT PER SCREW (191AM13)
FRONT VIEW OF ASSEMBLY
CAR M310330 ASSEMBLY
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1 PER SIDE OF
191AM13 - 981040 - NUT
27AM131 - 975209 - BOLT
IN SAME LOCATION EACH SIDE
CAR M310330 ASSEMBLY
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STEP #15 INSERT 2 FLANGE SCREWS (975204) PER SIDE THROUGH THE FRONT FRAME
EXTENSION AND THE LH AND RH FRAME EXTENSIONS. (REF. DIAGRAM 6 BELOW) STEP #16 SECURE THESE 4 SCREWS BY HAND WITH FLANGE NUT 976432
12
DIAGRAM 6
CAR M310330 ASSEMBLY
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27AM99 - 975121 - BOLT
191AM13 - 981040 - NUT
975204 - BOLT
189AM16 - 976432 - NUT
BOLT PLACEMENT DIAGRAM
CAR M310330 ASSEMBLY
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STEP #17 PLACE THE APPROPRIATE
EXTENSION ON THE TORQUE GUN. STEP #18 WITH MINIMUM TORQUE,
TIGHTEN THE TWO SCREWS
(27AM99) THAT WERE PREVIOUSLY
PLACED INTO THE TOP OF THE
ASSEMBLY TO SECURE THE
20904633 TO THE RH AND LH
FRAME EXTENSIONS.
RELIABLE METHOD
FLANGE SCREW 975209 IS
SECURED FIRST TO AVOID
FURTHER MOVEMENT OF
THE ASSEMBLY WHILE TIGHTENING
THE OTHER SCREWS
STEP #19 TIGHTEN ALL OTHER SCREWS
WITH MINIMUM TORQUE SO THEY ARE
NUT RUNNER TIGHT. STEP #20 REMOVE THE SPACER BAR
STEP #21 LOAD PART ONTO SKID
USING THE HOIST.
COMPLETED PART
CAR M310330 ASSEMBLY
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CAR M310330 ASSEMBLY