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 related panels and components.
- Remove the sealers and anti-corrosion materials from the repair area if necessary. Refer to Anti-Corrosion Treatment and Repair.
- Restore as much of the damage as possible.
- Cut the rear compartment panel at the rear edge of the number 5 crossbar.
- Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
- Remove the damaged rear compartment panel from the vehicle.
Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.
Note: Perform a full replacement only when a full frame rail assembly is installed. Use an overlap procedure for rail sectioning. The rear floor pan service part comes pre-cut to the correct length for replacement, and does not need to be modified.
Note: DO not damage any inner reinforcements or panels. Use caution not to damage the welds that attach the frame rail to the wheelhouse if you are not replacing the complete rail assembly.
Installation Procedure
- Prepare the mating surfaces as necessary.
- Drill 8 mm (5/16 in) plug weld holes along the front edge of the service part. Locate these holes 13 mm (1/2 in) from the edge of the service part spaced 40 mm (1.5 in).
- Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. Do not drill holes in the vertical flange along the wheelhouse area. This area will be bonded.
- Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.
- Apply bonding material Lord 108 to the vertical flanges in the wheelhouse areas only.
- Install and align the service part using 3-dimensional measuring equipment.
- Plug weld accordingly.
- To create a solid weld along the front of the service part with minimum heat distortion, make a 25 mm (1 in) stitch weld along the seam with 25 mm (1 in) gaps between them.
- Clean and prepare all welded surfaces.
- Apply sound deadeners as necessary.
- Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
- Apply the sealers and anti-corrosion materials to the repair area if necessary. Refer to Anti-Corrosion Treatment and Repair.
- Install all related panels and components.
- Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection.
- Enable the SIR system. Refer to SIR Disabling and Enabling.
Note: This part has structural weld-thru adhesive in the joint areas. Replace this with additional spot welds at the attachment points. This can be accomplished by adding an additional weld between each factory weld in all areas.
