GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Body and Accessories 🢒 Collision Repair 🢒 Rear Rail Underbody Gusset Replacement

Removal Procedure

    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. Object Number: 874146 Size: SH
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible. Refer to Dimensions - Body .
  5. 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. Object Number: 874152 Size: SH

    Important: Note the number and location of the factory welds for installation of the underbody gusset to the rear rail.

  6. Locate and drill out all the necessary factory welds.

    7. Object Number: 874156 Size: SH
  7. Remove the underbody gusset from the rear rail.

Installation Procedure

    Object Number: 874149 Size: SH

    Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1½ in) apart.

  1. Drill 8-mm (5/16-in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel.
  2. Prepare all mating surfaces as necessary.
  3. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.

    4. Object Number: 874156 Size: SH
  4. Position the underbody gusset to the rear rail.

    5. Object Number: 874146 Size: SH
  5. Plug weld accordingly.
  6. Clean and prepare all of the welded surfaces.
  7. Install all of the related panels and components.
  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 the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  11. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.