Front Rail End Replacement Corvette

Special Tools

J 42058 Frame Adapter Clamp

The service assemblies for the left and the right front frame rails are pre-sleeved, mild steel, hydro-formed parts.

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Remove the front impact bar. Refer to Front Bumper Impact Bar Replacement.
5. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.
6. Repair as much of the damage as possible to the factory specifications.
7. Use J 42058 to secure the vehicle if pulling and straightening are required.

Warning: Refer to Title not found in the Preface section.




8. Determine the sectioning joint location from the center of the rear upper radiator support bolt (1).



9. Measure 67 mm (2 5/8 in) (a) forward from the center of the rear upper radiator support bolt.



10. Mark the top of the frame rail at the sectioning location.
11. At the mark align a sliding square or similar tool (1) square to surface to the vertical walls of the frame rail.
12. Scribe a line to both sides of the frame rail.



13. Apply masking tape (1) to the scribe line completely around the frame rail.



14. Cut the frame rail at the rear edge of the tape line using a reciprocating saw or equivalent tool (1).



15. Remove the damaged frame rail end section (1).

1. Grind the existing frame rail sectioning location to a 45 degree angle.
2. Clean and prepare all of the welded mating surfaces.
3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refr to Anti-Corrosion Treatment and Repair.



4. Position the service frame section (1) to the existing frame.



5. Maintain a gap of one and one half frame rail metal thickness at the sectioning joint (1) and clamp in place.
6. Inspect the frame measurements three-dimensional to ensure proper position of the service frame section.




Note: Use a 25-mm (1-in) stitch weld to avoid minimal heat distortion.

7. Using a metal inert gas (MIG) welder, weld completely around the sleeve joint.
8. Install the front impact bar. Refer to Front Bumper Impact Bar Replacement.
9. Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair.

Note: DO NOT top coat any bonding surface. Use primer only on bonding surfaces. Refer to adhesive manufacturer's recommendations.

10. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
11. Install all related panels and components.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
13. Enable the SIR system. Refer to SIR Disabling and Enabling.

Front Rail End Replacement Z06, ZR1

Special Tools

J 42058 Frame Adapter Clamp

The service assemblies for the left and the right front end frame rails are pre-sleeved, 6063-T7 aluminum, hydro-formed parts, which correlate directly with the die mark located on the front frame rails.

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Remove the front impact bar. Refer to Front Bumper Impact Bar Replacement.
5. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.
6. Repair as much of the damage as possible to the factory specifications.
7. Use J 42058 to secure the vehicle if pulling and straightening are required.

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




8. Locate the die-mark (1) on the damaged frame rail.



9. At the die mark align a sliding square or similar tool square to surface to the vertical walls of the frame rail.
10. Scribe a line to both sides of the frame rail.



11. Apply masking tape (1) to the scribe line completely around the frame rail.




Note: Hand tools, saw blades and abrasives used for aluminum repairs should be dedicated for aluminum only to prevent contamination.

12. Cut the frame rail at the rear edge of the tape line using a reciprocating saw or equivalent tool (1).



13. Remove the damaged frame rail end section (1).

1. Grind the existing frame rail sectioning location to a 60 degree angle.

Note: Use a stainless steel brush to remove the oxide layer prior to welding.

2. Clean and prepare all of the welded mating surfaces.



3. Position the service frame section (1) to the existing frame.



4. Maintain a gap of one frame rail metal thickness at the sectioning joint (1) and clamp in place.




Note: 

•	Recommend 2 weld passes (root and cap).

•	Recommend wire alloy is 5356 and wire size is 0.035. The shielding gas is 100 percent Argon.

•	A 2 minute cooling down period is recommend for every 2 minutes or 100 mm (4 in) of welding.

5. Using a PULSED-MIG welder, weld 50 mm (2 in) stitch welds to the top and bottom of the sleeve joint.
6. Using a PULSED-MIG welder, weld 50 mm (2 in) stitch welds to the inner and outer vertical walls of the sleeve joint.
7. Inspect the frame measurements three-dimensional to ensure proper position of the service frame section.
8. Using a PULSED-MIG welder, complete the welding of the sleeve joint using the 2 minute cooling down period for every 2 minutes or 100 mm (4 in) of welding.
9. Install the front impact bar. Refer to Front Bumper Impact Bar Replacement.
10. Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair.

Note: DO NOT top coat any bonding surface. Use primer only on bonding surfaces. Refer to adhesive manufacturer's recommendations.

11. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
14. Enable the SIR system. Refer to SIR Disabling and Enabling.
15. Inspect the frame measurements three-dimensional to ensure proper position of the service frame section.