Important: If the damage exceeds the recommended area for sectioning and the rail cannot be straightened, the complete rail must be replaced.

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. Remove all related panels and components.
4. Restore as much of the damage as possible to factory specifications. Refer to Dimensions - Body .

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. Perform the necessary procedures to gain access to repair. Refer to Radiator Upper Support Replacement , Upper Rail Replacement , Radiator Lower Support Replacement , or to Front Wheelhouse Replacement .




Important: The additional 10 mm (13/32 in) metal measurements will be used to create a flange for welding the new service part to vehicle.

7. On the top of the rail, locate the last cut-out square (1). From the front edge of square, measure forward 47 mm (1 7/8 in) and scribe a line.
8. Add 10 mm (13/32 in) and scribe a second line. The second line 57 mm (2 1/4 in) is cut location.



9. On the inboard side of the rail, locate hole. Measure forward 54 mm (2 5/32 in) and mark location. Scribe a straight line on rail.
10. Measure forward 10 mm (13/32 in) and scribe a second line. The second line 64 mm (2 19/32 in) is the cut location.



11. On the outboard side of the rail, locate where brake line bolts to rail.
12. Remove bolt and bracket.
13. At larger hole, pull tape measure tight from forward edge of hole (2) and mark a line at 416 mm (16 in).
14. Scribe a line with a straight edge. Make it as square as possible to inboard and top rail markings.
15. Add 10 mm (13/32 in) and scribe a second line. The second line is the cut location, 426 mm (16 ¾ in).



16. Make certain all 3 sides are aligned.
17. Cut through all 3 sides of rail.
18. On the bottom of the damaged rail (1), scribe a line from the outboard to the inboard cut locations and cut remainder of the rail from the vehicle.
19. Remove the damaged section of the rail.

1. On the original rail, cut and remove 10 mm (13/32 in) of the outboard (1) and downward (2) turned flanges of the rail.
2. Cut 10 mm (13/32 in) gaps along the corners of the original rail.
3. Step the top, bottom and side tabs inward (3) to allow the service part to fit over the original rail.
4. Clean and prepare mating surfaces as necessary.
5. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces

1. Position the service part over the original rail.
2. Align and check fit with 3-dimensional measuring. Refer to Dimensions - Body



3. Stitch weld along the entire sectioning joint.
4. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
5. Go back and complete the stitch weld to create a solid weld joint with minimal heat distortion.
6. Complete the necessary procedures. Refer to Radiator Upper Support Replacement , Upper Rail Replacement , Radiator Lower Support Replacement , or to Front Wheelhouse Replacement .
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 and repair the 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.