GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 SSR 🢒 Body 🢒 Collision Repair 🢒 Front Fender Upper Rail 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: 1236539 Size: SH
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to Motor Compartment 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: 1236540 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 welds for installation of the front upper rail.
  7. Verify the existence of structural weld-through adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the front upper rail from the adjacent panels.

    8. Object Number: 1236543 Size: SH
  8. Remove the damaged front upper rail.

Installation Procedure

    Object Number: 1236548 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: 1236549 Size: SH
  5. Position the upper rail. Align and inspect for proper positioning. Refer to Motor Compartment in Dimensions - Body .

    6. Object Number: 1236551 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.