Removal Procedure
Sectioning of the inner reinforcement panel can only take place with
the outer door frame replacement or sectioning procedures. Section of the
outer door frame at the front hinge pillar requires a 40 mm (1 9/16 in)
offset from the inner reinforcement sectioning joint. The inner reinforcement
can serve as a backing plate for the outer panel sectioning.
Important: Sectioning the outer rocker panel requires a 100 mm (4 in)
backing plate for reinforcement (1). There are key structural areas
on the outer rocker panel where sectioning should not be performed. Sectioning
in these areas may compromise the structural integrity of the vehicle.
- Remove all related panels and components including the front door.
- Position all wiring out of the way to prevent damage.
- Remove sealers and anti-corrosion materials as necessary.
- On the original outer
door frame (1) measure down from the large wiring harness hole in the pillar
40 mm (1 9/16 in) and mark a horizontal line.
- Cut the outer door frame along this line for sectioning.
- Perform additional sectioning procedures as necessary to remove
damaged areas of the door frame opening.
- Locate, mark, and drill out all necessary factory welds. Note
the number of the welds for installation of the service panel (2).
- Remove the damaged section of the door frame opening.
Installation Procedure
- On the service part (2), mark a horizontal line to leave
a gap of one and one-half times the thickness of the metal at the section
joint.
- Cut the service panel along this line.
- Drill 8 mm (5/16 in) holes for plug welding in the
service part in the locations noted from the original panel.
- Drill holes for plug welding
along the sectioning cut on the service part (2).
- Locate these holes approximately 13 mm (½ in)
from the edge of the sectioning cut.
- Use the inner reinforcement (3) as a backing plate.
- Stitch weld along the entire joint (3).
- Make 25 mm (1 in) gaps between.
- Go back and complete the stitch weld. This will create a solid
joint with minimal heat distortion.
- Complete all other welds and sectioning procedures as necessary.
- Clean and prepare welded surfaces.
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.
- Prime with 2-part catalyzed primer.
- Apply sealers and anti-corrosion materials as necessary.
- Install all related panels and components.