For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- Remove all of the related panels and the components.
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Repair as much of the damage as possible. Refer to Dimensions - Body.
- Cut the rear rail along the rearward flange of the crossbar.
- Continue this cut around the rear rail.
- Drill out factory welds to rear floor.
- Remove the damaged component from the vehicle.
Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.
Warning: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.
Installation Procedure
- Use the original parts as a guide, mark a line on the service rail 35 mm (1-5/16 in) forward of the cut made to the original part. This will provide an overlap for welding the service section.
- Cut the service rail a long the marked lines and discard the unused section.
- Cut and remove approximately 35 mm (1-5/16 in) of the flanges on the service rail.
- Cut a 5 mm (1/4 in) gap approximately 35 mm (1-5/16 in) along the corners of the service rail to create tabs.
- Step the tabs inward to allow the service rail to fit inside the original rail.
- Position the modified service rail inside the original rail, allow 35 mm (1-5/16 in) of overlap.
- Check the position of the service rear rail section using 3-dimensional measuring equipment and tack weld in 3 locations along all 3 sides of the rail.
- Drill two 8 mm (5/16 in) holes for plug welding in each of the 3 sides of the rail approximately 30 mm (1-3/16 in) from the sectioning joint.
- Plug weld at each 8 mm (5/16 in) plug weld hole location.
- Stitch weld along the entire sectioning joint. Make welds along the seam with 25 mm (1 in) gaps between. Weld the gaps. Replace factory welds, as necessary.
- Clean and prepare the welded surfaces.
- Install all of the related panels and components.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Paint the repaired area. Refer to Anti-Corrosion Treatment and Repair.
- Enable the SIR system. Refer to SIR Disabling and Enabling.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
