Rear Floor Replacement Sectioning

Important: The damaged floor is cut along the rearward edge of the rear crossbar, and the service part is cut so that the new floor section extends to the front edge of the rear crossbar. This allows the two sections to overlap where the crossbar is attached.

1. Remove all related panels and components as necessary including the following:

•	Rear end panel

•	Quarter panels

•	Panel extensions

2. Remove the following as necessary:

•

Sealers

•	Sound deadeners

•	Anti-corrosion materials

3. Locate, mark and drill out all factory welds rearward of the rear crossbar including those along the lower edge of the wheelhousings. Note the number of welds for installation of the floor service assembly.

Important: Only drill out the factory welds rearward of the crossbar. Do not drill out the welds attaching the crossbar to the floor.




4. Cut the floor along the rear edge of the crossbar, take care not to damage the rear rails, crossbar or wheelhousings.
5. Remove the damaged floor section.

1. Cut the service part 1,050 mm (41 5/16 in) from the rear edge.
2. Prepare mating surfaces.
3. Check for proper fit of the floor service assembly. Allow it to overlap the original floor on top of the rear crossbar.
4. Mark the location of the rear rail and crossbar flanges on the bottom of the floor service assembly.

Important: When sectioning the rear rails and floor pan, it may be necessary to grind the top surface of the remaining sections for proper fit of the service floor.

5. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original floor.
6. Drill weld holes where the new floor section attached to the rear rail and crossbar flanges. These should be placed approximately 40 mm (1 1/2 in) apart.
7. Position the service assembly.
8. Check for proper fit and plug weld accordingly.
9. Clean and prepare welded surfaces.
10. Prime with two-part catalyzed primer.
11. Apply sealers and anti-corrosion materials as necessary.
12. Refinish as necessary.
13. Do not combine paint systems.

Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

14. Install all replated panels and components.