Disconnect OEM tail lights

Remove OEM tail lights

Remove reverse buzzer, cut from harness and keep

Photo of reverse buzzer removed with harness and mounting bolt. Ensure to keep the mounting bracket and bolt for remounting in the cab.

Remove OEM tail light harness from rear cross member.

Untie rear light harness from chassis extension and tie up in front of the second last cross member

Harness tied up

Using a 30mm socket and the tyre removal tool, lower the spare tyre and place on a pallet to be stored until the completion of truck.

Photo of tyre lowered

Remove spare tyre carrier and place in the bin.

Remove rear crossmember and plane in the steel bin.

Remove 4x chassis bolts and 2x shock bolts on either side.

Cable tie shocks out of the road to allow room for Magnet drill.

Set Mag drill up with a 16mm Broach cutter and drill 4x holes through crossmember to allow bolts to go through for subframe mounting.

Photo of which 4 holes needed drilling.

Apply masking tape to chassis between the holes where the last crossmember finishes.

Measure half way between holes 96 & 97 and project a square line down the chassis on both sides as shown.

Using an angle grinder and correct PPE, cut excess chassis starting at the bottom working your way up.

Cut all the way through except the corner. This will allow you to get help or hook up the crane to catch beams so they don’t fall.

After cutting off excess chassis, tidy up and round edge with a flappy disc. Once completed, clean with brake clean and spray black paint on chassis end and in the drilled holes to prevent rust.