For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling .
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Remove all related panels and components.
- Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Locate and drill out all factory welds. Note the number and location of the welds for installation of the rocker reinforcement.
- If sectioning the rocker outer panel, the rocker reinforcement can be sectioned a minimum of 150 mm (3 in) away from the outer panel sectioning joint. When sectioning a reinforcement use a piece of scrap from the original or new part to create a 50 mm (2 in) backing plate for the joint.
- Remove the damaged rocker reinforcement.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
- Prepare all mating surfaces as necessary.
- Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
- Position the rocker reinforcement to the vehicle using 3-dimensional measuring equipment. Clamp the rocker reinforcement into place. If sectioning, position the backing plate.
- Plug weld accordingly. To create a solid weld with minimum heat distortion at the sectioning joint, make 25 mm (1 in) welds with 25 mm (1 in) gaps between them. Then go back and complete the stitch.
- Clean and prepare all welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .
- Install all related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Enable the SIR system. Refer to SIR Disabling and Enabling .
Important: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.
Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld.