GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 SSR 🢒 Body 🢒 Collision Repair 🢒 Front Fender Upper Rail Sectioning

Removal Procedure

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

    Important: Sectioning procedures have been developed to simplify the repair of the upper tie-bar. If the damage exceeds the recommended area for sectioning, replace the complete upper fender rail.

  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: 1273411 Size: SH
  6. Locate the 2 die marks on the upper fender rail.

    7. Object Number: 1273413 Size: SH

    Important: Line up ¾ in masking tape with the point of each die mark arrow as shown.

  7. Apply masking tape over the die marks and around both sides of the upper fender rail.

    8. Object Number: 1273414 Size: SH

    Important: The tape edge facing the front of the vehicle is the proper cut location.

  8. Cut the upper fender rail along the front edge of the tape using a cut-off wheel or equivalent.

    9. Object Number: 1273415 Size: SH

    Important: Do NOT damage any inner panels or reinforcements.

  9. Locate and drill out all factory welds in front of the sectioning location. Note the number and location of the welds for installation of the replacement fender rail section.

    10. Object Number: 1273417 Size: SH
  10. Verify the existence of structural weld-through adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the upper fender rail section from the adjacent panels.

    11. Object Number: 1273418 Size: SH
  11. Remove the upper fender rail section.

    12. Object Number: 1273420 Size: SH
  12. Remove the masking tape and grind to bare metal a 25 mm (1 in) strip at the sectioning location.

Installation Procedure

    Object Number: 1273422 Size: SH
  1. On the service upper fender rail, locate the 2 die marks.

    2. Object Number: 1273423 Size: SH
  2. Apply masking tape along the back of each die-mark arrow as shown in the figure.

    3. Object Number: 1273424 Size: SH
  3. Cut the upper fender rail along the back edge of the tape using a cut-off wheel or equivalent.

    4. Object Number: 1273426 Size: SH
  4. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut. Locate these holes 13 mm (½ in) from the edge and spaced approximately 26 mm (1 in) apart.

    5. Object Number: 1273427 Size: SH
  5. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in locations noted from the original panel.
  6. Replace the structural adhesive with an additional plug weld between the existing plug welds, where necessary.
  7. Prepare all mating surfaces as necessary.
  8. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces

    9. Object Number: 1273428 Size: SH
  9. Position the upper fender rail section. Refer to Motor Compartment section in Dimensions - Body .

    10. Object Number: 1273429 Size: SH
  10. Plug weld accordingly.
  11. Clean and prepare all welded surfaces.
  12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  13. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  14. Install all related panels and components.
  15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  16. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.