The roof panel is welded to the steel roof (1) structure on the sides, and spot welds on the windshield and back glass flanges. Replacement of the roof panel can be performed using conventional procedures, however, the windshield and back glass must be removed.

1. Remove all related panels and components.

Important: Use care when cutting to protect adjacent panels. Make sure to cut inboard of the roof structure.

2. Visually inspect and restore as much of the damage as possible to the 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 and location of welds for installation of the service assembly.
5. Cut the original roof panel along the sides, leave approximately 75 mm (3 in) remaining attached.
6. Cut the adhesive with an appropriate tool and remove the remaining portion of the original panel.

1. Clean and prepare the attaching surfaces for welding (1).
2. Drill 8 mm (5/16 in) holes for plug welding along the windshield and back glass edges for the service panel as noted from the original panel.
3. Drill the holes for plug welding along the sides every 40 mm (1 ½ in).
4. Position the service panel and check the fit.
5. Plug weld accordingly.

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.

6. Prime with two-part catalyzed primer.
7. Install all related panels and components.