GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 SSR 🢒 Body 🢒 Collision Repair 🢒 Windshield Frame Header Front 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.
  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: 1237835 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 header panel.

    7. Object Number: 1237840 Size: SH
  7. Using a grinder or an equivalent tool, remove the MIG welds on each end of the header.

    8. Object Number: 1237844 Size: SH
  8. Verify the existence of structural weld-through adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the outer header panel from the inner header panel.

    9. Object Number: 1237853 Size: SH
  9. Remove the damaged header panel.

Installation Procedure

    Object Number: 1237857 Size: SH
  1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary at the locations noted from the original header 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: 1237861 Size: SH
  5. Position the header panel. Refer to Windshield Opening in Dimensions - Body .
  6. Plug weld accordingly.

    7. Object Number: 1237865 Size: SH
  7. Continuous weld 2 slots in each side of the outer header panel.

    8. Object Number: 1237868 Size: SH
  8. Clean and prepare all welded surfaces.

    9. Object Number: 1237869 Size: SH
  9. Apply the sealers and 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 system. Refer to SIR Disabling and Enabling in SIR.