For 1990-2009 cars only
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 all related panels and components.
- Repair as much of the damage as possible. Refer to Dimensions - Body .
- Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Locate and drill out all the necessary factory welds.
- Remove the #5 cross bar.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Note the number and location of the factory welds for installation of the #5 cross bar.
Installation Procedure
- Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
- Prepare all mating surfaces for welding as necessary.
- Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
- Position the #5 cross bar.
- Plug weld accordingly.
- Clean and prepare all of the welded surfaces.
- Install all of the related panels and components.
- 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 .
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Enable the SIR system. Refer to SIR Disabling and Enabling.
Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.
