GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Corvette 🢒 Body and Accessories 🢒 Roof 🢒 Folding Top Side Rail Replacement

Removal Procedure
  1. Remove the folding top and place the top on a clean flat surface. Refer to Folding Top Replacement .
  2. Remove the following components from the rear side rail:
    3. 2.1. The headliner screws
    2.2. The headliner elastic strap screws
    2.3. The glare cover elastic strap screws
    2.4. The defogger wire
  3. Remove the weatherstrip and retainer from the rear side rail. Refer to Folding Top Weatherstrip Retainer Replacement

    4. Object Number: 784535 Size: SH

    Caution: Wear safety glasses in order to avoid eye damage.

  4. Drill out the rivets to the top cover side flap from the rear side rail.
  5. Lift the flap and drill out the rivet attaching the tension cable flag.
  6. Drill out the top cover rivet to the bottom of the rear side rail.

    7. Object Number: 784517 Size: SH
  7. Remove the protective pad from the weatherstrip attaching nuts on the #5 bow.
  8. Remove the weatherstrip attaching nuts from the #5 bow.

    9. Important: You are not required to completely remove the weatherstrip.

  9. Remove the weatherstrip from the bottom of the rear side rail and from the end of the #5 bow. You are not required to completely remove the weatherstrip.
  10. Remove the top cover and the protective cover from the bottom of the rear side rail and from the front edge of the #5 bow.
  11. Drill out the rivets from the protective cover elastic strap on the rear side rail.
  12. Drill out the extension bracket rivet from the #5 bow on the rear side rail.
  13. Remove the extension bracket screws from the rear side rail on the #5 bow.
  14. Remove the rear side rail screws from the center side rail.

    15. Object Number: 289896 Size: SH
  15. Remove the rear side rail.

Installation Procedure

    Object Number: 289896 Size: SH
  1. Install the rear side rail.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the center side rail screws to the rear side rail.

    3. Tighten
    Tighten the screws to 19 N·m (14 lb ft).

  3. Install the extension bracket screws to the #5 bow.

    4. Tighten
    Tighten the screws to 13 N·m (10 lb ft).


    Object Number: 784535 Size: SH
  4. Rivet the #5 bow to the extension bracket on the rear side rail. Verify that both sides of the rivet are flat.
  5. Rivet the protector elastic strap to the rear side rail.
  6. Rivet the tension cable flag to the rear side rail. The rolled side of the flag must face forward.
  7. Rivet the top cover to the bottom of the rear side rail.
  8. Rivet the top flap to the rear side rail.
  9. Install the retainer and the seal to the rear side rail. Refer to Folding Top Weatherstrip Retainer Replacement .
  10. Install the screws attaching the headliner elastic strap to the rear side rail.

    11. Tighten
    Tighten the screws to 2 N·m (18 lb in).

  11. Install the headliner screws to the rear side rail.

    12. Tighten
    Tighten the screws to 2 N·m (18 lb in).

  12. Connect the defogger wire to the rear side rail.
  13. Install the folding top to the vehicle. Refer to Folding Top Replacement .
  14. Position the folding top to the original position.