GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 SSR 🢒 Body 🢒 Collision Repair 🢒 Floor Panel Number 5 Cross Bar 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: 1272980 Size: SH
  3. Remove all related panels and components including the end gate. Refer to Endgate Replacement in Body Rear End.
  4. Repair as much of the damage as possible to factory specifications. Refer to the Rear Compartment section of Dimensions - Body .
  5. Loosen all mounting bolts that secure the body to the frame. Remove all of the bolts EXCEPT the 2 in the front tie bar and the 2 bolts under the front hinge pillar. Refer to Frame Cushion or Insulator Replacement in Frame and Underbody.

    6. Object Number: 1272981 Size: SH

    Important: Note the location and remove or disconnect any component that could be damaged while raising the rear portion of the body off of the frame.

  6. Lift the rear of the body approximately 15 cm (6 in) off of the frame onto a wooden block as shown.

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

  7. 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.

    8. Object Number: 1272985 Size: SH
  8. Locate and drill out all of the factory welds in the underbody. Drill completely through all of the layers of metal.

    9. Object Number: 1272986 Size: SH
  9. Locate and drill out all factory welds in the rear compartment floor. Drill completely through all of the layers of metal.

    10. Object Number: 1272988 Size: SH
  10. Verify the existence of structural weld-through adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the crossbar from the adjacent panels.

    11. Object Number: 1272989 Size: SH
  11. Remove the damaged cross bar.

Installation Procedure

    Object Number: 1272990 Size: SH

    Important: Do NOT drill plug weld holes in the service part.

  1. Prepare all attachment surfaces as necessary.
  2. Apply 3M® Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
  3. Replace the structural adhesive with an additional plug weld between the existing plug welds, if necessary.

    4. Object Number: 1272993 Size: SH
  4. Position the service part.

    5. Object Number: 1272995 Size: SH
  5. Plug weld accordingly.
  6. Clean and prepare all welded surfaces.
  7. 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.
  8. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.

    9. Notice: Refer to Fastener Notice in the Preface section.

  9. Lower the body to the frame and reattach the mounting bolts.

    10. Tighten
    Tighten the bolts to 140 N·m (103 lb ft).

  10. Install all related panels including the end gate. Refer to Endgate Replacement in Body Rear End.
  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.