GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 SSR 🢒 Preface 🢒 Cautions and Notices 🢒 Rear Compartment Lock Pillar Gusset Replacement

Removal Procedure

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


    Object Number: 1244743 Size: SH
  1. When replacing the lock pillar gusset, you must remove and replace the outer quarter panel.
  2. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  4. Remove all related panels and components including the outer quarter panel. Refer to Quarter Outer Panel Replacement .
  5. Repair as much of the damage as possible to factory specifications. Refer to Roof Stowage Compartment and Rear Compartment in Dimensions - Body .

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

  6. Note the location and remove the sealers and the anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

    7. Object Number: 1244738 Size: SH

    Important: Do NOT damage any inner panels or reinforcements.

  7. Locate and drill out all factory welds. Note the number and the location of the welds for installation of the service part.

    8. Object Number: 1244742 Size: SH
  8. Verify for the existence of structural weld-through adhesive. Refer to Structure Adhesive Identification . If necessary use a chisel to separate the gusset from the adjacent panels.

    9. Object Number: 1244743 Size: SH
  9. Remove the damaged gusset.

Installation Procedure

    Object Number: 1244775 Size: SH
  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 each existing plug weld 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: 1244777 Size: SH
  5. Position the service part. Refer to Roof Stowage Compartment and Rear Compartment in Dimensions - Body .

    6. Object Number: 1244780 Size: SH
  6. Plug weld accordingly.
  7. Install the outer quarter panel. Refer to Quarter Outer 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.