Removal Procedure
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
- Remove all related panels and components.
- Visually inspect and restore as much of the damage as possible to factory
specifications.
- Remove the following as necessary:
• | Anti-corrosion materials |
- Use an air chisel to remove the rear engine mount.
- Locate and drill out resistance welds in the torque box panel. Drill
through one layer of metal ONLY.
- Locate welds that secure the rail to the floor pan from the underside
of the vehicle.
- Use a 3 mm (1/8 in) drill bit to drill through the floor
and mark welds for removal.
- Separate the floor pan reinforcement vertical flange from inside the
lower rail. Care must be taken to not damage the flange.
- Drill out factory welds along the lower flange on the floor pan reinforcement
and at the wheelhouse. Note that the flanges overlap the rail.
- From inside of vehicle, use an 8 mm (5/16 in) drill bit
to drill through the floor pan and the reinforcement inside the vehicle.
- Remove the damaged rail.
Installation Procedure
- Prepare all mating surfaces as necessary.
Inspect for proper fit of the new rail.
- Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
- Position the new rail in place and check for proper alignment. Use 3-dimensional
measuring.
- With the new rail in place, plug weld all holes created from the removal
process.
- Where the floor inner panel does not contact the floor pan, use a ball
pein hammer to flatten the inner panel against the floor pan.
- Plug weld floor to new rail in remaining areas.
- Clean and prepare welded surfaces.
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.
- Apply approved anti-corrosion primer.
- Apply sealers and refinish as necessary.
- Install all related panels and components.