GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2009 🢒 Wave 🢒 Body Repair 🢒 Collision Repair 🢒 Front Compartment Front Rail Replacement

Removal Procedure

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

Note: 

   • The front lower rail is joined to the wheelhouse and radiator support, if forms the base for the front suspension, engine, transmission and others. Therefore, replacement of the component affects the front wheel alignment and maintains the rigidity of the front section.
   • Sectioning procedures have been developed to simplify the repair of the lower rails, as long as the damage rearward of the sectioning location can be repaired to factory specifications.
   • Failure to follow the instructions may lead to improper rail sectioning, which may compromise the structural integrity of the vehicle.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling.
  2. Disconnect the negative battery cable.

    3. Object Number: 2029625 Size: SH
  3. Remove all of the related panels and components.
  4. Repair as much of the damage as possible to factory specifications.
  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.
  6. Perform the necessary procedures to gain access to the repair.

    7. Note: Note the number and location of the factory welds for installation of the full rail service part.

  7. Locate and drill out all the necessary factory welds.
  8. Remove the damaged frame rail section from the vehicle.

Installation Procedure

    Object Number: 2029626 Size: SH
  1. Cut the new frame rail assembly where it will be sectioned align it with the body, then set the wheelhouse panel.
  2. Drill 6 8 mm (5/16 in) plug weld holes in the rail.
  3. Clean and prepare all of the welded surfaces.
  4. Apply weld-thru coating as necessary. Refer to Anti-Corrosion Treatment and Repair.
  5. Inspect the frame measurements 3-dimensional to ensure proper position of the service rail section.

    6. Object Number: 2029625 Size: SH
  6. Plug weld accordingly at each plug weld location.
  7. Stitch weld along the entire sectioning joint. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
  8. Complete the stitch weld.
  9. Clean and prepare all of the welded surfaces.
  10. Install all of the related panels and components.
  11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  12. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
  13. Connect the negative battery cable.
  14. Enable the SIR system. Refer to SIR Disabling and Enabling.