GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Lumina Ute 🢒 Body Repair 🢒 Frame and Underbody 🢒 Engine Rear Crossmember Replacement

Removal Procedure

    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.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling .

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Remove the cargo liner. Refer to Cargo Box Liner Replacement .
  4. Remove the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
  5. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
  6. Remove the rear body rail cover. Refer to Pickup Box Cover Side Rail End Cover Replacement .
  7. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

    8. Important: Note the number and location of the factory welds for installation of the rear crossmember.

    Important: The graphic is from underneath the vehicle looking rewards.


    Object Number: 2021905 Size: SH
  8. Locate, mark and drill out the spot welds in rear crossmember to the rear floor panel and subframe assemblies (1).

Installation Procedure

    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).

  1. Clean and prepare the mating surfaces of both parts of the panel.

    2. Important: Secondary sealer must be applied to the perimeter of all flanges. Secondary sealer must be applied to all welds/joints that where originally covered by secondary sealer.


    Object Number: 2021906 Size: SH

    Important: Position the rear crossmember aligning the datum holes (1)

  2. Weld the rear crossmember to the rear floor panel and subframe assembly (2).
  3. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  4. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  5. Install the rear body rail cover. Refer to Pickup Box Cover Side Rail End Cover Replacement .
  6. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
  7. Install the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
  8. Install the cargo liner. Refer to Cargo Box Liner Replacement .
  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 .