GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 SSR 🢒 Body and Accessories 🢒 Collision Repair 🢒 Cargo Box Inner Side Panel Replacement

Removal Procedure

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


    Object Number: 1246087 Size: SH
  1. The replacement cargo box side panel is serviced as a complete assembly, including the cargo cover mounting bracket. If damage is less severe the cargo box side panel may be removed without removing the outer quarter panel or the outer wheelhouse.
  2. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  4. Remove all related panels and components.
  5. Repair as much of the damage as possible to factory specifications. Refer to Rear Compartment in Dimensions - Body .

    6. Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

  6. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

    7. Object Number: 1246079 Size: SH

    Important: Do not damage any inner panels or reinforcements.

  7. Locate and drill out all factory welds. Note the number and location of welds for installation of the service side panel.

    8. Object Number: 1246084 Size: SH
  8. Verify the existence of structural weld-through adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the side panel from the adjacent panels.

    9. Object Number: 1246087 Size: SH
  9. Remove the damaged side panel.

Installation Procedure

    Object Number: 1246092 Size: SH
  1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in locations noted from the original panel.
  2. Replace the structural adhesive with an additional plug weld between the existing plug welds, where necessary.
  3. Prepare all mating surfaces as necessary.
  4. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces

    5. Object Number: 1246094 Size: SH
  5. Position the service side panel. Align and inspect for proper positioning. Refer to Rear Compartment in Dimensions - Body .

    6. Object Number: 1246096 Size: SH
  6. Plug weld accordingly.
  7. Clean and prepare all welded surfaces.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  10. Install all related panels and components.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  12. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.