Rear Rail Replacement Crossbar

Important: The rear crossbar connects the two rear rails for added strength and rigidity (1) consists of two pieces, a left and right side, that can be ordered separately. The crossbar should only be replaced at factory seams.

1. Remove all related panels and components.
2. Visually inspect and restore as much of the damage as possible to factory specifications.
3. Remove the following as necessary:

•

Sealers

•	Sound deadeners

•	Anti-corrosion materials

4. Locate, mark and drill out all factory welds. Note the number of welds for installation of the crossbar service part.
5. Remove the damaged crossbar.

1. Prepare mating surfaces.
2. Check for proper fit of the service part (1).
3. Drill 8 mm (5/16 in) plug weld holes on the service part as necessary in the locations noted from the original assembly.
4. Position the service part.
5. Check fit of body dimensions. Use three-dimensional measuring equipment.
6. Plug weld accordingly.
7. Clean and prepare welded surfaces.
8. Prime with two-part catalyzed primer.

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.

9. Apply sealers and anti-corrosion materials as necessary.
10. Install all related panels and components.

Rear Rail Replacement Full

1. The left and right rails are available as complete sub-assemblies. Each consists of outer panels (4), rear reinforcement (2), inner reinforcements (1) and all necessary component mounting brackets. The rear extension (3), rear reinforcement and mounting brackets are also available separately and be easily serviced at factory seams.The rear extension is also included with the rear end panel service assembly. Additionally, sectioning procedures can be used to repair the portion of the rail rearward of the crossbar.

Remove all related panels and components including the rear suspension and seat.

2. Visually inspect and restore as much of the damage as possible to factory specifications.
3. Remove the following as necessary:

•

Sealers

•	Sound deadeners

•	Anti-corrosion materials

4. Locate, mark and drill out or chisel all factory welds. Note the number of welds for installation of the service assembly.
5. Remove the damaged rear rail assembly.

1. Prepare mating surfaces.
2. Check for proper fit of the rear rail service assembly.
3. Drill 8 mm (5/16 in) plug weld holes on the service assembly in the locations noted from the original assembly.
4. Position the service assembly. Each consists of outer panels (4), rear reinforcement (2), inner reinforcements (1) and all necessary component mounting brackets. The rear extension (3), rear reinforcement and mounting brackets are also available separately and be easily serviced at factory seams.The rear extension is also included with the rear end panel service assembly.
5. Check to ensure proper fit. Use three-dimensional measuring equipment.
6. Plug weld accordingly.
7. Clean and prepare welded surfaces.
8. Prime with two-part catalyzed primer.

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.

9. Apply sealers and anti-corrosion materials as necessary.
10. Install all related panels and components.