Quarter Panel Sectioning Utility

Important: The quarter panel can be serviced as a complete panel or sectioned. When complete panel replacement is performed, the roof panel must be removed and replaced. For sectioning, the quarter panel can be replaced by making sectioning cuts at the window pillars and using a 5 mm (2 in) backing plate (2) with a gap of 1 ½ times the metal thickness (1) at the sectioning joint.

1. Remove all related panels and components.
2. Restore as much of the damage as possible to factory specifications.
3. Note the location and remove the following as necessary:

•

Sealers

•	Sound deadeners

•	Anti-corrosion materials

Important: Do not damage the inner panels or reinforcements.

4. Cut the quarter panel in the location where sectioning is to be performed
5. Locate and drill out all factory welds. Note the number and location of the welds for installation of the service part.
6. Remove the damaged quarter panel section.

1. Cut the replacement quarter panel in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of 1 ½ times the metal thickness at the sectioning joint.
2. Create a 50 mm (2 in) backing plate (2) from the unused portion of the service part (1). Trim the backing plate as necessary to fit behind the sectioning joint.
3. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the remaining original panel. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1 in) apart.

Important: In any area damaged beyond recognition, space plug weld holes every 40 mm (1 in) apart.

4. Drill 8 mm (5/16 in) plug weld holes in the service panel as necessary in the locations noted from the original panel and along the sectioning cut.

Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

5. Prepare all attachment surfaces as necessary.
6. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all bare metal surfaces.
7. Fit the backing plate halfway into the sectioning joint, clamp and plug weld to the vehicle.
8. Align the quarter panel to adjacent panels using 3-dimensional measuring equipment. Leave a gap of 1½ times the metal thickness at the sectioning joint.
9. Plug weld accordingly.
10. To create a solid joint with minimal heat distortion, make 25 mm (1 in) stitch welds along the seam with 2 mm (1 in) gaps between them, then go back and complete the stitch weld.
11. Clean and prepare all welded surfaces.

Important: Prior to refinishing, refer to publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

12. Apply the following as necessary:

•	An approved anticorrosion primer

•	Sound deadening materials

•

Sealers

•	Refinish materials

13. Install all related panels and components.

Quarter Panel Sectioning Avalanche

1. Remove all related panels and components.
2. Restore as much of the damage as possible to factory specifications.

Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

3. Note the location and remove the following as necessary:

•	The sealers

•	The sound deadeners

•	The anti-corrosion materials




4. Apply 25 mm (1 in) wide tape (1) along the upper edge of the quarter panel at the roof line.




Important: Do not damage any inner panels or reinforcements.

5. Cut the quarter panel at the bottom edge of the tape.



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



7. Remove the damaged quarter panel, leaving a 25 mm (1 in) flange attached to the roof.

1. Trim and discard the upper mounting flange on the service quarter panel so that it will fit over the 25 mm (1 in) flange left from the original panel.



2. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the service part. Locate these holes 13 mm (1/2 in) from the edge and spaced 40 mm (1 1/2 in) apart.

Important: In any area damaged beyond recognition, space plug weld holes every 40 mm (1 1/2 in) apart.

3. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut.



4. Prepare all attachment surfaces as necessary.
5. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all bare metal surfaces.

Sealing the Quarter Panel Caution: The fuel filler opening must be properly sealed prior to positioning the quarter panel. Failure to properly seal the quarter panel could result in exhaust gas leakage into the interior of the vehicle causing personal injury.

Caution: Properly seal the fuel filler opening before you position the quarter panel. Failure to seal the opening could allow exhaust gas to leak into the interior of the vehicle, causing personal injury.

6. Install GM P/N 12399117 Sealing Strip between outer wheelhouse and quarter panel gas door pocket.
7. Apply internal sealers (1) in the locations noted from the removal procedure.



8. Position the quarter panel to the vehicle.



9. Plug weld accordingly.
10. 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.



11. Clean and prepare all welded surfaces.

Important: Prior to refinishing, refer to publication GM 4901MD GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

12. Apply the following as necessary:

•	The approved anti-corrosion primer

•	The sound deadeners

•	The sealers

13. Refinish as necessary.
14. Install all related panels and components.