GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Aztek - FWD 🢒 Body 🢒 Collision Repair 🢒 Front Lower Rail Sub-Assembly Replacement

Removal Procedure

    Object Number: 767130 Size: SH
  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:
    4. • Sealers
    • Sound deadeners
    • Anti-corrosion materials

    Object Number: 767133 Size: SH
  4. Separate the floor pan reinforcement  (1) weld flanges from the inside of the lower rail. Care must be taken not to damage the weld flanges.

    5. Important: Do not damage any inner panels or reinforcements

  5. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front lower rail.

    6. Object Number: 767135 Size: SH
  6. Remove the damaged rail.

Installation Procedure

    Object Number: 767136 Size: SH
  1. Prepare the mating surface of the floor pan reinforcement  (1).
  2. Turn the weld flanges outward  (2) to be welded to the front lower rail.
  3. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the removal.

    4. Object Number: 767137 Size: SH
  4. Position the front rail reinforcement inner  (1).
  5. Prepare all attachment surfaces as necessary.
  6. Apply weld-thru primer to all bare-metal surfaces.

    7. Object Number: 767139 Size: SH
  7. Position the service part.

    8. Object Number: 767140 Size: SH
  8. Plug weld accordingly.
  9. Clean and prepare all of the welded surfaces.

    10. Object Number: 767142 Size: SH
  10. Apply the following as necessary:
    11. • Anti-corrosion materials
    • Sound deadeners
    • Sealers
  11. Refinish as necessary.
  12. Install all related panels and components.