Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Important: When replacing a rail in its entirety, the weld flange that mates with the wheelhouse must be bent upward. The service assembly is supplied with this flange in a horizontal position.

1. Visually inspect and restore as much of the damage as possible to factory specifications.
2. Remove all related panels and components including gas tank and rear suspension.
3. Remove the following as necessary:

•

Sealers

•	Sound deadeners

•	Anti-corrosion materials

4. Remove inner wheelhouse braces, 2 per side, to gain access to hidden spot welds.
5. Drill out all factory welds at the floor pan and inner wheelhouse locations.
6. Remove the damaged rail.
7. Prepare all mating as necessary.

1. Measure from outside edge of horizontal flange on service part inward 30 mm and mark every 2 inches.
2. Connect markings with straight edge to create a radius line.
3. Notch metal in appropriate locations along the edge of panel to the radius line, to easily bend the flange upward along radius line.
4. Create upturned flange by bending with pliers.
5. Hammer and dolly to bend into a vertical position.
6. Drill 8 mm (5/16 in) holes duplicating number and location from original rail.

1. Position the new rail in place.
2. Secure rail by installing seat belt bolt through factory hole into rail, then drawing rail into place by tightening bolt.
3. Check for proper alignment using three-dimensional measuring.
4. With the new rail in place, plug weld all the holes created from the removal process.
5. Plug weld floor to new rail in remaining areas.
6. Clean and prepare all welded surfaces.

Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations. For further information or to order manual, please call 1-800-269-5100.

7. Apply an approved anti-corrosion primer.
8. Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturer's recommendations.
9. Install all related panels and components.