Rear Compartment Panel Replacement Full Replacement

Important: Relocate and secure the wiring for access to structural panels. Take care not to damage brake lines or fuel lines.

1. Visually inspect and restore as much of the damage as possible to factory specifications.
2. Remove all related panels and components including gas tank and exhaust system.
3. Remove the rear trunk carpet.
4. Remove the rear seats.
5. Remove the tail panel.
6. Locate and remove two inner wheelhouse braces (1,2).



7. Identify weld locations.
8. Drill out welds through one layer of metal only
9. Remove the sealers.
10. Remove the sound deadeners.
11. Remove the anti-corrosion materials as necessary.
12. Locate factory seam at front edge of crossbar at rearward of seatback.
13. Locate and mark all factory welds.

Drill out factory welds which secure rear compartment panel to floor pan and rails, through one layer only.

14. Note the number and location of welds for installation of the service panel.
15. Drill completely through welds that attach the rear compartment to the inner wheelhouses.

Important: All rear compartment welds can be drilled out and installed to the wheelhouse area from the outside of the vehicle.

16. Remove the damaged panel.
17. Prepare mating surfaces with a suitable weld-through primer.

1. Lay 19.05 mm (3/4 in) masking tape along contour of floor pan service part where it will mate to the wheelhouse (1).
2. Notch the metal in appropriate locations at radii to allow flange to easily bend upward on the inside edge of masking tape (2).



3. Bend service part flange (1) upward using suitable flanging tool.
4. Use hammer and dolly to complete preparation.
5. Create 25 mm (1 inch) downward turned flange (2) for securing floor pan to quarter panel from end of wheelhouse to tail panel.
6. Drill 8 mm (5/16 in) plug weld holes at locations noted from original floor pan.

Important: In areas damaged beyond recognition, space plug weld holes every 40 mm (1 ½ in) apart.

7. Prepare mating surfaces for welding.

Important: Carefully bend but do not crease the front corners of the new panel to allow it to fit between the inner wheelhouses (1).

1. Position the service floor pan.
2. Check for proper fit according to body dimensions and clamp in place (2).
3. Plug weld accordingly.
4. Install both inner wheelhouse braces.
5. Clean and prepare all welded surfaces.

Important: Prior to refinishing, refer to GM 4901M--2000 "GM Approved Refinish Materials" for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

6. Apply an approved anti-corrosion primer.
7. Apply a full-bodied caulk, to form a consistent, leak-proof seal around perimeter of rear compartment panel.
8. Refinish as necessary.
9. Install all related panels and components.