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 .
- 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 attaching the tail lamp inner filler panel to body side (1).
- Remove the tail lamp filler panel from the vehicle.
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 location of the factory adhesive and sealants for installation of the tail lamp inner filler panel.
Installation procedure
- Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when disassembling.
- Clean and prepare the mating surfaces of both parts of the body side panel assembly.
- Apply the primary sealer to the tail lamp filler panel.
- Weld the tail lamp filler panel to the rear quarter panel and rear floor panel (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 endgate. Refer to Endgate 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 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 plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).
Important: Follow the adhesive manufacturer's instructions during the assembly process. Heat must be applied as per the manufacturer's specifications to cure the adhesives and to expand the sealing baffles.
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.
