Rear Rail Replacement Upper

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. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .
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 in Paint and Coatings.

Important: Do not damage any inner panels or reinforcements.

6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the rear rail upper.
7. Remove the damaged rear rail upper.

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.
1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from 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. Position the rear rail upper to the vehicle using 3-dimensional measuring equipment. Clamp the rear rail upper into place.
5. Plug weld accordingly.
6. Clean and prepare all welded surfaces.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
8. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
9. Install all related panels and components.
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.