Toyota Collision Repair Information - Welding High Strength Steel (H.S.S.)

COLLISION REPAIR INFORMATION
FOR THE TOYOTA DEALER
TITLE:
WELDING HIGH STRENGTH
PAGE 1 of 5
STEEL (H.S.S.)
SECTION:
WELDING
BULLETIN #27
MODELS:
ALL TOYOTA MODELS
DATE:
JULY 1988
In today’s body shop environment high strength steel (H.S.S.) body parts are frequently
welded during collision damage repairs. Typical uses for H.S.S. are the front cross
member, front body outer pillar, floor side member and door side impact protection beam.
Because H.S.S. is used in these areas of potential high stress, repairs must be done
properly to maintain the structural integrity of the vehicle.
Two types of H.S.S. are used. Solution hardened H.S.S. is used for door panels, hood
outer panel, etc., while precipitation hardened H.S.S. is used for door impact beams and
bumper reinforcements. It is not necessary to distinguish solid solution hardened steel from
ordinary steels for repair purposes.
The location of H.S.S. parts can be found in the Toyota Repair Manual for Collision
Damage under the Body Panel Construction section. A sample chart from the 1987 Camry
Collision Repair Manual is on page 3 of this bulletin. A list of available Toyota Collision
Repair manuals is on page 4.
REPAIR GUIDELINES
H.S.S. and ordinary steel parts in Toyota vehicles are welded using the same methods.
The following precautions apply:
S Use either spot welding or MIG/MAG (shield gas) welding. MIG/MAG (shield
gas) welding should only be done by an experienced body shop person.
S Only braze body components previously brazed at the factory and as indicated in
the Toyota Repair Manual for Collision Damage.
S Do not use an oxy–acetylene torch for fusion welding auto bodies. The large
heat affected zone may destroy galvanized coatings and cause excessive panel
distortions. In addition, an oxy–acetylene torch will reduce the strength and
increase the brittleness of H.S.S.

---

WELDING HIGH STRENGTH STEEL (cont’d)
PAGE 2 of 5
REFERENCE MATERIALS
The following manuals should be readily available in the body shop:
S Toyota Fundamental Body Repair Procedures Manual
S Complete set of Toyota Repair Manuals for Collision Damage
TOOLS
Proper tools are mandatory for H.S.S. repair. Tools include:
S MIG/MAG welder
S Spot welder
S H.S.S. spot weld cutter that will cut 8mm and 10mm holes
S Air saw
S Plasma cutter
S Air power chisel with panel cutter
S Hole punch
S Head protector
S Dust mask
S Face protector
S Vise grip pliers
S Weld through primer (see page 5 of this bulletin)
S Ear plugs
S Car cover for glass and interior
WELDS
Four types of welding are required in the repair of Toyota vehicles:
S Spot
S Continuous
S Plug
S Braze
Technicians doing repair work must be proficient in doing all four types of welding since all
four are used in various locations throughout the vehicle. The Toyota Repair Manuals for
Collision Damage show the location and type of welds that must be used. The correct
number and type of welds must be used to ensure structural integrity.
PROCEDURE
The complete in–depth procedure for welding H.S.S. and ordinary steel can be found in the
Toyota Fundamental Body Repair Procedures manual for the applicable vehicle. The basic
procedure requires:
1. Removal of auxiliary parts
4. Position new parts
2. Removal of damaged parts
5. Welding
3. Prepare new parts
6. Finishing of welded areas.

---

WELDING HIGH STRENGTH STEEL (cont’d)
PAGE 3 of 5
BODY PANEL CONSTRUCTION — High Strength Steel (H.S.S.) Parts

---

WELDING HIGH STRENGTH STEEL (cont’d)
PAGE 4 of 5
TOYOTA SERVICE PUBLICATIONS
PART NUMBER
DESCRIPTION
3643–8E
Fundamental Painting Procedures
BRM00–2E
Fundamental Collision Repair
3643–1E
Tercel 2WD
3643–2E
Tercel 4WD
3643–4E
Corolla 83–87
36182
Celica/Supra 82–86
BRM00–1E
Celica 86–88
BRM00–5E
Supra 86–88
3643–3E
Camry 83–86
36118
Cressida 81–84
3644–1E
Cressida 85–88
3644–2E
Cressida Wgn. 85–88
3644–oA
MR2 85–88
BRM00–3E
Van 84–87
BRM01–1U
Tercel Coupe 87–88
BRM01–0U
Camry 87
BRM00–7U
Tercel Sedan 87–88
BR012
Corolla 88
BRM00–6E
FX/FX 16 87–88
BRM00–9E
Supra Sport Roof 86–88
BRM00–8E
MR2 T–Roof 85–88
You may order these on your TDN through the non–parts ordering system.

---

WELDING HIGH STRENGTH STEEL (cont’d)
PAGE 5 of 5
WELD–THROUGH PRIMER SUPPLIERS *
1.
HTP “Cold Galvanizing Compound”
Part No. 12022
HTP America, Inc.
261 Woodwork Lane
Palatine, IL 60067
2.
TTE “Dan–Prime”
Transnational Technology Enterprises, Inc.
3541 Old Conejo Road, #107
Newbury Park, CA 91320
3.
Anchor Brand “Spray–Galv”
NASCO
Welding Equipment and Safety Supplies
Chicago, IL
4.
3M “Weld–Thru Coating”
Part No. 051131–05913
3M Automotive Trades Division
St. Paul, MN
5.
Kent “Spotweld Primer”
Part No. 50190
Kent Industries
4500 Euclid Ave.
Cleveland, OH 44103
* There may be other sources for this material that are not listed here.

---