Front Bumper Impact Bar Replacement Corvette

Special Tools

J 42058 Frame Adapter Clamp

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 or reposition the wiring to avoid damage.
5. Repair as much of the damage as possible to the factory specifications.



6. Use J 42058 to secure the vehicle if pulling and straightening are required.
7. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.




Note: Do not cut into the frame rails.

8. Cut the welds around the perimeter of the frame rail ends. Cut the welds favoring the impact bar side of the joint.
9. Remove the damaged impact bar.



10. Extract pieces of the impact bar which are left attached to the rail ends.
11. Straighten and deburr the rail ends. Keep the perimeter and shape of the rail end as original as possible.

1. Temporarily position the impact bar for proper fit and alignment.



2. Clean and prepare all of the welded mating surfaces.
3. Apply GM-approved weld-thru coating or equivalent as necessary and to the inside of the rail ends. Refer to Anti-Corrosion Treatment and Repair.
4. Position the bumper impact bar to the vehicle using 3-dimensional measuring equipment.




Note: If no trace of the original welds is present, follow the pattern specified for welding the side rails to the impact bar.

5. Using a metal inert gas (MIG) welder, stitch weld the front bar to the frame rail ends.
6. Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair.
7. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
8. Install all related panels and components.
9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
10. Enable the SIR system. Refer to SIR Disabling and Enabling.

Front Bumper Impact Bar Replacement Z06, ZR1

Tools Required

J 42058 Frame Adapter Clamp

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. Repair as much of the damage as possible to the factory specifications.
5. Use J 42058 to secure the vehicle if pulling and straightening are required.
6. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.




Note: 

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

•	When removing welds, favor the bumper bar side of the weld joint.

7. Locate and remove all factory welds (1) attaching the front bumper bar to the front frame rails. Note the location of the welds for installation of the new bumper bar.



8. Remove the damaged bumper bar (1).



9. Remove pieces of the bumper bar which are left attached to the rail ends.
10. Straighten and deburr the rail ends. Keep the perimeter and shape of the rail end as original as possible.

Note: Due to welding accessibility, it may be necessary to weld the triangle brackets (1) to the bumper bar prior to installation of the bumper bar.

1. Dry fit the bumper bar for proper fit and alignment before welding.

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. Install the front bumper bar (1).
4. Position the bumper bar to the vehicle using 3-dimensional measuring equipment.




Note: Recommend wire alloy is 5356 and wire size is.035. The shielding gas is 100 percent Argon.

A two minute cooling down period is recommend for every 2 minutes or 100 mm (4 in) of welding.
5. Using a PULSED-MIG (P-MIG) welder, weld (1) the bumper bar to the frame rail ends duplicating the factory welds.
6. Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair.
7. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
8. Install all related panels and components.
9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
10. Enable the SIR system. Refer to SIR Disabling and Enabling.