Front Wheelhouse Replacement Full Front Replacement

1. Remove panels and components as necessary for access.
2. Restore as much of the damage as possible to factory specifications.
3. Remove all sealers and anti-corrosion materials as necessary.



4. Place 25 mm (1 in) wide masking tape on the forward contour of the wheelhouse at the flange where it attaches to the cowl panel.
5. Cut the wheelhouse along the forward edge of the masking tape (1) to leave a 25 mm (1 in) tab extending forward from the cowl panel. This will provide an overlap for welding the service part to the original wheelhouse without welding directly to the cowl panel.
6. Locate, mark, and drill out the factory welds attaching the wheelhouse assembly at the following:

•	Upper rail inner panel

•	Cowl panel

•	Radiator support

•	Lower front rails

7. Remove the damaged wheelhouse assembly.

1. Clean and prepare surfaces to be welded.



2. Cut the flange off the service part that is normally welded to the cowl panel (1).
3. Drill 8 mm (5/16 in) holes for plug welding in the locations noted from the original assembly.
4. Drill holes for plug welding every 40 mm (1½ in) along the cut edge to be attached to the tab remaining from the original assembly (2).

Important: Watch for flammable materials when welding to the interior panels of the vehicle.

5. Prepare all mating surfaces for welding as necessary.
6. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
7. Position the wheelhouse assembly using three-dimensional measuring equipment.
8. Plug weld wheelhouse as necessary.
9. Clean and prepare all bare metal surfaces.
10. Apply the following as necessary:

•

Sealers

•	Anti-corrosion materials

•	Sound deadeners

•	Two-part catalyzed primer

•

Top-coat

Important: Prior to refinishing, refer to publication GM 4901M-D-01 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

11. Install the panels and components previous removed for access.