Now that you have repaired the leaks in the trunk with 'How-To's": Rear Trunk Leak and Trunk Leak 2 it's time to repair the damage done to the carpeted area that covers the spare tire, the board that's warped because of all that water that got in there.
So lets get on with it. You can get the part from the dealer's parts department or go to Home Depot or Lowe's and buy the board to replace it with.
We'll start with the part number/s that maybe needed to be replaced for this project from your dealer:
Clip A (Top part to hold carpet to the board) - part number 91535-SR2 -003ZB
or 402081
Clip B (Bottom part to hold carpet to the board) - part number 91536-SR2-000
or 402082
Floor Mat (Carpet)- part number 84630-SR2-960ZA
Board Assembly - part number 84521-SR2-960
Or the whole thing ready to drop in:
Lid Assy. (Board,carpet & clips) - part number 84520-SR2-960ZA
Tools needed:
Jig Saw
Sand Paper or small flat file
Small screw drivers (to remove clips holding carpet on)
Spray Adhesive
Knife or a Model knife (to remove foam pads from board)
A small router would be handy but not necessary
Now for the board, you will need to get a 1/8 inch. - 4x8 Hard Board, this is the same as a peg board w/o the holes in it.
First cut a piece off a quarter of an inch taller then the height of old board from the trunk (about 29 1/4 inches should work) to make it easier to work with. Carefully remove the clips that hold the carpet to the old board with two small screw drivers, wedging them against the edges and then push on the center part to pop it out. Next with the carpet removed lay the old board on it so you can trace it out onto the new board laying it as flat as you can to get so it to be the same size as the old one. Also at this time mark the holes for the clips that hold the carpet on.
Next using a jig saw carefully cut out the pattern you marked. After it is
cut use a drill the holes for the carpet clips with a 5/16 inch bit, slide
the bit back and forth some to clean out the cutouts, test fit the bottom
part of the clip, it should fit in fairly tight. After that's done you can
now finish up on any of the rough edges left with sandpaper or a flat file.
With everything else done at this point, it's now time to reinstall the carpet
with the clips and finished up with the project.
Now carefully remove the old foam pads from the old board and mark where they
go on the new board, using some spray adhesive glue them back onto the new
board.
Now you should be ready to drop the unit back in your trunk and sit back and
enjoy. No more warped trunk cover.
By: GEO