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 the repair. Refer to Rear End Panel Replacement and Rear Compartment Panel Sectioning

Important: Do not damage any inner panels or reinforcements.




7. Mark the cut location, by measuring from the rear edge of the oval hole rearward (1) 270 mm (10 5/8 in).
8. Cut the rear rail section.



9. Remove the damaged rear rail section.

1. Mark the cut location on the service rail by measuring 240 mm (9 7/16 in) from the rear edge of the oval hole rearward (1).
2. Cut the rear rail service part.



3. Cut and remove 30 mm (1 3/16 in) from the flanges on either side of the service section rail to create 30 mm (1 3/16 in) tabs (1).
4. Cut 5 mm (1/4 in) wide gaps in the bottom corners (2).



5. Step the tabs inward (1) to allow the service rail section to fit inside of the original rear rail.

Important: The metal of the rear rail is of a heavy gage. However, the tabs can be created using the appropriate tools.

6. Weld the tabs together along the lower edges (2).




Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1 ½ in) apart.

7. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the original rail. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1 1/2  in) apart.
8. Prepare all mating surfaces as necessary.
9. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces



10. Position the sectioned rear rail service part.



11. Plug weld accordingly.



12. Stitch the weld sectioning joint.
13. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld.
14. Clean and prepare all welded surfaces.
15. Complete the necessary procedures. Refer to Rear End Panel Replacement , Rear Compartment Panel Sectioning .
16. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
17. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
18. Install all related panels and components.
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
20. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.