Important: Use the Offset Lap-Joint method to perform front rail repairs.

Important: This procedure is used when damage to the frame rail is limited to the portion forward of the cowl (front of dash). The front of dash sectioning area is exposed by modifying floor pan extension panels to access all sides of the rail. This repair can be performed with the engine suspended in place. Check SMC front of dash panel for cracks or areas that may need to be re-sealed.

Important: Save any and all brackets, mounting studs, and accessories for re-use as necessary.

1. Remove all related panels and components to provide access to the recommended sectioning area of rail.
2. Locate stitch welds and resistance welds that secure the upper floor pan extension panel to the rail and the tunnel brace.



3. Remove welds as necessary and pry up extension panel to expose rail.
4. Apply 50 mm (2 in) tape to lower floorpan extension panel where SMC floor panel stops and floorpan extension begins.

Important: The lower floorpan extension panel is to be reinstalled 50 mm (2 in) forward of the SMC floorpan. This will eliminate the potential to de-bond the floorpan when re-installing the floorpan extension panel.




5. Using a die grinder, cut along the forward edge of tape to create a 50 mm (2 in) flange.
6. Cut stitch welds along the rail and drill out the resistance welds along the tunnel brace.

Remove floorpan extension panel.

7. Determine the location to perform the sectioning; be sure to stay within the recommended areas.
8. Cut the damaged rail accordingly.
9. Using a die grinder, cut through the stitch welds that attach the tunnel brace to the frame rail. Make cuts favoring the rail side of the welds.
10. Remove the damaged rail portion.
11. Clean and prepare all surfaces for assembly as necessary.
12. Perform offset lap-joint sectioning as required.

1. Replace lower floorpan extension panel.

1.1.	Trim to fit.

1.2.	Tuck the new panel inside of the 50 mm (2 in) flange created from the original extension.

2. Locate and align front edges of panel.



3. Stitch weld to rail to duplicate factory welds.
4. Plug weld panel to tunnel brace as necessary to replace factory spot welds.
5. Check front of dash and floor panel areas for cracked or broken bonding. Repair and reseal as necessary.
6. Apply anti-corrosion materials to all inner surfaces as necessary.

•	Do not combine paint systems.

•	Refer to paint manufacturer's recommendations.

7. After sectioning repairs are completed, attach panels and components as necessary.