Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling .
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Remove the cargo liner. Refer to Cargo Box Liner Replacement .
- Remove the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
- Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
- Remove the endgate. Refer to Endgate Replacement .
- Remove the rear bumper centre support. Refer to Rear Bumper Fascia Center Support Replacement .
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Locate, mark and drill out the spot welds in the rear end panel assembly to the rear floor and rear crossmember assemblies (1).
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Caution: Refer to Safety Glasses Caution in the Preface section.
Caution: Refer to Foam Sound Deadeners Caution in the Preface section.
Caution: Refer to Battery Disconnect Caution in the Preface section.
Important: Note the number and location of the factory welds for installation of the rear end panel.
Installation Procedure
- Clean and prepare the mating surfaces of both parts of the panel.
- Align the rear end panel assembly using the datum points and weld (1) rear end panel to the vehicle.
- Install the rear bumper centre support. Refer to Rear Bumper Fascia Center Support Replacement .
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
- Install the rear bumper centre support. Refer to Rear Bumper Fascia Center Support Replacement .
- Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
- Install the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
- Install the endgate. Refer to Endgate Replacement .
- Install the cargo liner. Refer to Cargo Box Liner Replacement .
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Enable the SIR system. Refer to SIR Disabling and Enabling .
Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.
Important: If the location of the original spot weld holes cannot be determined, or if structural weld-thru adhesive is present, space the puddle weld holes every 32 mm (1¼ in).
Important: Secondary sealer must applied be to the perimeter of all flanges. Secondary sealer must be applied to all welds/joints that were originally covered by secondary sealer.
