GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 SSR 🢒 Body 🢒 Collision Repair 🢒 Roof Front Header Inner Panel Replacement

Removal Procedure

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

  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    3. Object Number: 1237832 Size: SH
  3. Remove all related panels and components including the outer header panel. Refer to Windshield Frame Header Front Panel Replacement .
  4. Repair as much of the damage as possible to factory specifications. Refer to Windshield Opening in Dimensions - Body .

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

  5. 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.

    6. Object Number: 1244433 Size: SH

    Important: Do NOT damage any inner panels or reinforcements.

  6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front header inner panel.

    7. Object Number: 1244435 Size: SH
  7. Verify the existence of structural weld-through adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the damaged panel from the upper A-pillars.

    8. Object Number: 1244436 Size: SH
  8. Remove the damaged header inner panel.

Installation Procedure

    Object Number: 1244438 Size: SH

    Important: If the location of the original plug welds cannot be determined, or where structural weld-through adhesive was present, space the plug weld holes every 40 mm (1½ in) apart.

  1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
  2. Replace the structural adhesive with an additional plug weld between 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: 1244440 Size: SH
  5. Position the front header inner panel. Refer to Windshield Opening in Dimensions - Body .

    6. Object Number: 1244443 Size: SH
  6. Plug weld accordingly.
  7. Install the windshield frame header panel. Refer to Windshield Frame Header Front Panel Replacement .
  8. Clean and prepare all welded surfaces.
  9. Apply the sealers and the anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  10. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  11. Install all related panels and components.
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  13. Enable the SIR. Refer to SIR Disabling and Enabling in SIR.