GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2001 🢒 SL1/SC1/SW1 🢒 Body and Accessories 🢒 Collision Repair 🢒 Panel Assembly - Rear End Replacement

Panel Assembly - Rear End Replacement Sedan


    Object Number: 860657 Size: MF
  1. Note the amount and location of the spot welds.
  2. Remove the sealer and drill spot welds from:
    3. 2.1. The panel assembly rear compartment rear
    2.2. The panel assembly rear compartment side left and right
    2.3. The rail assembly rear compartment longitudinal
  3. Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
  4. Apply a permanent underbody sealant.

    5. Important: Ensure that proper corrosion protection processes are used on all repair areas.

  5. Prime with a 2-part catalyzed primer.
  6. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
  7. Clean the surface for welding and grind the primer off of the new part at the connecting points. Apply 3M® Weld-Thru Coating P/N 05913, or equivalent, to all areas to be welded.
  8. Measure and align the panel assembly rear end. Clamp into place.
  9. Use a MIG to plug the weld.

Panel Assembly - Rear End Replacement Coupe


    Object Number: 861882 Size: MF
  1. Remove the sealer.
  2. Drill the spot welds from:
    3. 2.1. The panel assembly-rear compartment rear
    2.2. The panel assembly-rear compartment side left and right
    2.3. The gutter assembly-rear compartment side
    2.4. The rail assembly-panel compartment longitudinal
  3. Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
  4. Apply a permanent underbody sealant.

    5. Important: Ensure that proper corrosion protection processes are used on all repair areas.

  5. Prime with a 2-part catalyzed primer.
  6. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
  7. Clean the surface for welding and grind the primer off of the new part at the connecting points. Apply 3M® Weld-Thru Coating P/N 05913, or equivalent, to all areas to be welded.
  8. Measure and align the panel assemble rear end. Clamp into place.
  9. Use a MIG to plug the weld.

Panel Assembly - Rear End Replacement Wagon


    Object Number: 860706 Size: MF
  1. Note the amount and location of the spot welds.
  2. Drill the spot welds from:
    3. 2.1. The panel quarter inner lower rear
    2.2. The panel back body outer lower
    2.3. The panel assembly rear compartment rear
    2.4. The bar assembly #6
    2.5. The panel assembly frame body side rear
  3. Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
  4. Apply a permanent underbody sealant.

    5. Important: Ensure that proper corrosion protection processes are used on all repair areas.

  5. Prime with a 2-part catalyzed primer.
  6. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
  7. Clean the surface for welding and grind the primer off of the new part at the connecting points. Apply 3M® Weld-Thru Coating P/N 05913, or equivalent, to all areas to be welded.
  8. Measure and align the panel assembly rear end. Clamp into place.
  9. Use a MIG to plug the weld.