For 1990-2009 cars only
Removal Procedure
- Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- 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 in Paint and Coatings.
- Locate and drill out all factory welds. Note the number and location of the welds for installation of the No.2 cross bar extension.
- Remove the damaged No.2 cross bar extension.
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Important: Do not damage any inner panels or reinforcements.
Important: The rear flange connecting the No.2 cross bar extension to the rail will have to be chiseled apart due to the location of the spot welds. The new service part will have the flange bent outward for welding access.
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 No.2 cross bar extension to the vehicle using 3-dimensional measuring equipment. Clamp the No.2 cross bar extension into place.
- Plug the weld accordingly.
- 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 in Paint and Coatings.
- Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
- Install all related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.
Important: If the location of the original plug weld holes cannot 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.Important: If reusing the original No.2 cross bar extension, bend the rear flange outward for welding access.
