Bulkhead removal thread?

supertreeman

Well-known member
Have searched but no luck..Anyone know of a bulkhead replacement thread? Ill likely be replacing one soon when the 110 arrives. Footwells are pretty bad so not sure I want to mess around with patch panels.

Looking at parts manual it looks like this can be done without removing the roof. Sounds like a PIA so Id like to read as much about it as I can first.
 

JimC

Super Moderator
Staff member
Looks like you just made one! It’s not so bad, it’s just a ton of work. Many many sub-tasks. You can definitely replace it without removing the roof, but that’s small consolation.

This is my rough order of operations:
1) Remove front sheet metal
remove fender flares
separate outer fender skins
extract light/ancillary wiring from wings
drain coolant
drain PS or suspend reservoir
remove misc like washer reservoir, etc
2) strip bulkhead engine side
remove heater housing
remove brake pedal/booster/lines
remove clutch tower/lines
disconnect steering shaft
3) strip bulkhead interior side
remove floors and tunnel
remove doors
disassemble dash from top down
unplug/extract dash harness, pull through into interior side
4) remove bulkhead
detach windshield from roof and bulkhead, remove
remove bulkhead brackets from chassis
unfasten sills
remove large bolts on bulkhead outriggers, supporting bulkhead, taking note of door gap spacing/number of washers by outrigger

assembly is the reverse!
 

supertreeman

Well-known member
Yeah. Seems like a lot of work but I think it'll be worth it in the end. Thanks for the list that will be very helpful
 

jymmiejamz

Founding Member
Callsign: KN4JHI
If it’s just the foot wells, I would repair them rather than replace the entire bulkhead. If you replace the bulkhead you’re going to be doing some serious paint work to the truck to get it to match. For just the footwell, you can get an aerosol can of the original color and save yourself a trip to the body shop.
 

supertreeman

Well-known member
Getting closer to actually undertaking this project..anyone have any first hand experience with the Proline Bulkheads. Looking at the LHD 300TDI Proline vs other brands. Wondering if they fit close to the original or if there's much fiddling about in order..
 

miket961

Well-known member
I recently stripped down my front end for the first time. Its not terribly complicated, no special tools, and simple to figure out for the most part.

Recommend a large breaker bar and a cut off wheel to get the difficult ones. A tool I recently picked up is a 3" battery cut-off tool. This thing gets in all the tight spaces my 7" and 4" can't get.

I'm terrible at drilling out rusted screws...
 

Z.G

Well-known member
Getting closer to actually undertaking this project..anyone have any first hand experience with the Proline Bulkheads. Looking at the LHD 300TDI Proline vs other brands. Wondering if they fit close to the original or if there's much fiddling about in order..

Mixed feedback so far, for the price it's hard to beat(genuine is like around double). Some have gone in no issue, some have gone in with slight modifications, and 1 has been warped to a point we had to warranty replace it. There have been a few stupid issues that make no sense, like holes drilled in the wrong spots, but overall we've had success with them.
 
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