GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Cobalt 🢒 Body 🢒 Collision Repair 🢒 Underbody Rear Side Rail Replacement

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Remove all related panels and components.
  4. Repair as much of the damaged area as possible. Refer to Dimensions - Body .
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

    6. Object Number: 1544561 Size: SH

    Important: Note the number and location of the factory welds for installation of the wheelhouse - rear inner.

  6. Locate and drill out all the necessary factory welds.

    7. Object Number: 1544562 Size: SH
  7. Remove the rear rail.

Installation Procedure

    Object Number: 872744 Size: SH

    Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.

  1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the locations noted from the original panel.
  2. Prepare all mating surfaces for welding as necessary.
  3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

    4. Important: The service part includes an inner rocker rear extension. The rear rail can be installed with or without the extension.

  4. If an extension panel is not required, drill out the spot welds.

    5. Object Number: 874177 Size: SH
  5. Remove the extension panel if necessary.

    6. Object Number: 1544562 Size: SH
  6. Position the rear rail to the vehicle using 3-dimensional measuring equipment. Clamp the rail in place.

    7. Object Number: 1544561 Size: SH
  7. Plug weld accordingly.
  8. Clean and prepare all of the welded surfaces.
  9. Install all of the related panels and components.
  10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  11. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  13. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.