GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Corvette 🢒 Body and Accessories 🢒 Collision Repair 🢒 Front 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. Remove the front impact bar. Refer to Front Bumper Impact Bar Replacement .
  5. Remove the side door opening. Refer to Side Door Opening Frame Replacement .
  6. Remove the front floor panel. Refer to Floor Panel Replacement .
  7. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  8. Restore as much of the damage as possible to the factory specifications. Refer to Dimensions - Body , Measurements - Underbody .
  9. Check the front of the dash panel, floor panels, and all other Sheet Molded Compound (SMC) for cracks or areas that may need to be repaired or resealed. Refer to Gouge or Puncture Repair , Rigid Plastic Part Repair Materials in Plastic Panel Information and Repair.

    10. Object Number: 860985 Size: SH
  10. Remove the damaged section of frame rail within the shaded area.

Installation Procedure

    Caution: Refer to Collision Sectioning Caution in the Preface section.


    Object Number: 870416 Size: SH
  1. Determine the sectioning joint location within the recommended area.

    2. Object Number: 870423 Size: SH
  2. Cut the new frame section from the new frame rail assembly.
  3. Perform the sleeved butt-joint sectioning. Refer to Sleeved Butt Joint Repair .
  4. Install the front impact bar. Refer to Front Bumper Impact Bar Replacement .
  5. Clean and prepare all of the welded surfaces.
  6. Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  7. Install the front floor panel. Refer to Floor Panel Replacement .
  8. Install the side door opening. Refer to Side Door Opening Frame Replacement .
  9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  10. Install the engine. Refer to Engine Replacement .
  11. Install all related panels and components.
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  13. Enable SIR system. Refer to SIR Disabling and Enabling in SIR.