Help With Flammable Foam

Posted on 09 January 2018 Print

Customer satisfaction is a major contributing factor to what goes into a new vehicle. One of the biggest demands from customers is a quiet passenger compartment. There are different ways of achieving a quiet cabin, like sound deadener pads, acoustic windshields, and specifically placed speakers that cancel noise. One method that is seen on every modern vehicle is noise vibration and harshness (NVH) foam.

NVH foam fills pillars, rockers, and quarter panels. Many times, this foam is extremely flammable and needs to be removed prior to applying any heat to the area. However, getting this foam out is not always that easy. Limited access to the inside of the panels can make it nearly impossible to get foam out of certain areas.

The Chrysler Pacifica body repair manual has a procedure titled, "Polyurethane Foam Removal." This procedure covers different options for removing foam. If the methods given will not work for the repair you are performing, an option is given for either cutting or drilling a hole to gain access. The cutting method calls for cutting a U-shaped window, then folding it open to get at the foam. After the foam is removed, the hole is closed with welding or a structural adhesive patch.

The other option is to drill a one inch access hole. After the foam is removed, the bare metal should be touched up with epoxy primer, and a body plug is installed. The Polyurethane Foam Removal procedure can be found at: stellantisiop.com.

Related I-CAR Courses

Course Noise, Vibration, and Harshness (NVH) Materials

  • I-CAR Just In Time: Cybertruck Tuesday, 11 March 2025

    Sometimes seeing is understanding, that’s why I-CAR's technical team created the Just in Time video series to guide you through a variety of collision repair topics from ADAS and EVs to repair tips...

  • GM Repair Insights: Winter 2025 Monday, 10 March 2025

    The winter edition of General Motors (GM) Repair Insights magazine is now available.

  • Refinishing Park Assist Sensors: Genesis Friday, 7 March 2025

    Park assist sensors are part of the park assist system, just one of many advanced driver assistance systems (ADAS) found on vehicles today. Damaged sensors are typically replaced and may require...

  • Refinishing Park Assist Sensors: Hyundai Friday, 7 March 2025

    Park assist sensors are part of the park assist system, just one of many advanced driver assistance systems (ADAS) found on vehicles today. Damaged sensors are typically replaced and may require...

  • Structural Straightening: Rivian Wednesday, 5 March 2025

    What should you do when a damaged Rivian comes into your repair facility? Can you measure it? Can it be straightened? What needs to be replaced?

  • Bumper Cover Repair With ADAS: Genesis Thursday, 27 February 2025

    A simple bumper repair on a modern vehicle may not be as simple as it seems. New technologies like blind spot monitoring, adaptive cruise control, and other advanced driver assistance systems (ADAS)...

  • Bumper Cover Repair With ADAS: Hyundai - UPDATE Thursday, 27 February 2025

    A simple bumper repair on a modern vehicle may not be as simple as it seems. New technologies like blind spot monitoring, adaptive cruise control, and other advanced driver assistance systems (ADAS)...

  • I-CAR Repairers Realm: SATA New Equipment And Technologies - Now Available Wednesday, 26 February 2025

    I-CAR staff discussed recent developments in SATA equipment and technology.

  • Calibration Research Tips: Ford/Lincoln Park Assist Operation Check - UPDATE Thursday, 20 February 2025

    While searching for information on advanced driver assistance systems (ADAS) on an OEM repair information site, you may come across unique calibration procedures or events. These events can vary by...

  • Honda Has Released The 2026 Passport Body Repair News Wednesday, 19 February 2025

    Honda has released a Body Repair News bulletin for the 2026 Passport. This document contains at-a-glance information for this model.