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 .
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
- Remove the cargo liner. Refer to Cargo Box Liner Replacement .
- Remove the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
- Remove the filler tube. Refer to Filler Tube Replacement .
- Remove the fuel tank. Refer to Fuel Tank Replacement .
- Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
- Remove the endgate. Refer to Endgate Replacement .
- Remove the rear muffler assembly. Refer to Exhaust Muffler Replacement - Left Side and/or Exhaust Muffler Replacement - Right Side .
- Remove the rear crossmember. Refer to Engine Rear Crossmember 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 all factory welds attaching the rear muffler hanger bracket assembly to the rear crossmember (1).
- Remove the rear muffler hanger bracket assembly.
- Locate, mark and drill out all factory welds attaching the rear muffler hanger bracket assembly to the rear frame (1).
- Remove the rear muffler hanger bracket assembly.
Caution: Refer to Approved Equipment for Collision Repair 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.
Caution: Refer to Vehicle Lifting Caution in the Preface section.
Caution: Refer to Safety Glasses Caution in the Preface section.
Important: Note the number and location of welds for installation of the service assembly.
Important: Note the number and location of welds for installation of the service assembly.
Installation Procedure
- Align the rear muffler hanger bracket assembly using the datum points (1).
- Weld the rear muffler hanger bracket assembly to the rear frame (1).
- Weld the rear muffler hanger bracket assembly to the rear crossmember (1).
- 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 crossmember. Refer to Engine Rear Crossmember Replacement .
- Install the rear muffler assembly. Refer to Exhaust Muffler Replacement - Left Side and/or Exhaust Muffler Replacement - Right Side .
- Install the endgate. Refer to Endgate Replacement .
- Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
- Install the filler tube. Refer to Filler Tube Replacement .
- Install the fuel tank. Refer to Fuel Tank Replacement .
- Install the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
- Lower the vehicle.
- 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 can not be determined, or if structural weld-thru adhesive is present, space the puddle weld holes every 32 mm (1¼ in).
Important: Secondary sealer must be applied to the perimeter of all flanges. Secondary sealer must be applied to all welds/joints that were originally covered by secondary sealer.
Important: Secondary sealer must be applied to the perimeter of all flanges. Secondary sealer must be applied to all welds/joints that were originally covered by secondary sealer.
