Floor Pan Corrosion (Rust) Perforation in Battery Compartment (Install Repair Panel)

Some customers may comment on corrosion (rust) in the floor pan in the area where the battery is located.

This condition may be caused by a weeping of acid from the battery or from a battery vent tube that has become dislodged.

Repair the damaged area by installing a repair panel. Also, clean any area of the floor pan where acid may have been present with a solution of baking soda and water. Rinse and dry the area thoroughly.

Important: Clean the repair area of battery acid by dusting the area with baking soda and lightly spraying with water to neutralize acid. Clean the repair area completely and let dry thoroughly.

1. Remove the battery cables and battery.
2. Remove the battery hold down bracket.
3. Remove the sealers and anti-corrosion materials from the repair area, as necessary.
4. Set the part in place and outline the edge of the part with a marker.
5. Remove the part and draw a line 19 mm (0.75 in) in from the outline.

Notice: Cover the interior to protect it from sparks before grinding.

6. Cut the floor out on the line that was just marked.
7. Grind the mating surfaces down to the bare sheet metal, removing all galvanized coating.
8. Pre-fit the metal panel and pre-drill the four corners where the rivets will be necessary.
9. Apply a 3/8" bead of adhesive, P/N 12378567, around the perimeter of the floor.
10. Install rivets so the new part conforms to the floor pan.
11. Brush adhesive squeeze-out around the perimeter leaving no gaps.
12. Install a new battery hold down bracket if necessary.

Important: Any bare sheet metal around the perimeter should have adhesive applied to it for corrosion protection.

13. Raise the vehicle and brush adhesive around the perimeter leaving no gaps.
14. Lower the vehicle.
15. After the adhesive has set for 90 minutes, raise the vehicle and clean the adhesive with lacquer thinner to remove the tacky film.
16. Sand and paint the bottom and top of the battery tray.

Information for the 2005 GM Approved Refinish Materials booklet is now online at the GM GOODWRENCH WEB SITE ONLY. Printed books have been discontinued.

•	Go to www.gmgoodwrench.com

•	Click on GM Collision Parts.

•	Click on GM Technical Repair Information

•	Click on Paint Shop

17. Apply undercoating to the bottom of the repair.
18. Install the battery and battery cables.

Important: The floor pan repair panel kit contains a replacement section of the floor pan. The adhesive needs to be ordered at the time of the repair.

For vehicles under warranty, use: