For 1990-2009 cars only
Removal Procedure
- Remove all related panels and components.
- Restore as much of the damage as possible to factory specifications.
- Note the location and remove the following as necessary:
- Locate and mark for sectioning of the front hinge pillar and the center pillar. By measuring from the lower edge of the guide holes (1) downward 30 mm (1 3/8 in).
- Locate and mark for sectioning of the rear lock pillar with quarter panel removed (2).
- Scribe a line horizontally to the rocker.
- Cut the panel where sectioning is to be performed.
- Locate and drill out all factory welds. Note the number and location of welds for installation of the rocker panel.
- Remove the damaged rocker panel.
| • | Anti-corrosion materials |
| • | Sound deadeners (1) |
| • | Sealers |
Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Cut the replacement service part in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one half times the metal (1) thickness at the sectioning joint.
- In the rear lock pillar create a 50 mm (2 in) backing plate (1) from the unused portion of the door frame opening. Trim the backing plate as necessary to fit behind the sectioning joint.
- Use the lower hinge reinforcement (2) as the backing plate in the front hinge pillar and the center hinge pillar.
- Drill 8 mm (5/16) plug weld holes along the sectioning cut on the remaining original part.
- Drill 8 mm (5/16) plug weld holes as necessary in locations noted from the original panel and along the sectioning cut.
- Prepare all attachment surfaces as necessary.
- Apply weld-thru primer to all bare-metal surfaces.
- Fit the backing plate (3) halfway into the sectioning joint (1) clamp and plug weld to the vehicle (2).
- Align the rocker panel using three-dimensional measuring equipment.
- Plug weld accordingly.
- To create a solid weld with minimum distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then complete the stitch weld.
- Clean and prepare all welded surfaces.
- Apply the following as necessary:
Important: In any area damaged beyond recognition, space plug weld holes every 40 mm (1 ½ in) apart.
Important: Prior to refinishing, refer to publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.
| • | Anti-corrosion materials |
| • | Sound deadeners (1) |
| • | Sealers |
