Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Sectioning procedures can be used to repair the rear rail if just the portion rearward of the crossbar is damaged. Unique service parts are available for sectioning. The sub-assembly consists of the outer rail panel .

Important: If damage exceeds the recommended area for sectioning and the rail cannot be straightened, the complete rail assembly must be replaced.

1. Remove the fuel tank. Refer to Fuel Tank Replacement.



2. Remove all related panels and components.
3. Visually inspect and restore as much of the damage as possible to factory specifications.
4. Remove sealers and anti-corrosion materials as necessary.
5. Locate, mark, and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
6. Use a straight edge to scribe a line around the rail.
7. Cut the damaged rail (1).
8. Remove the damaged section of the rail.

Important: Note the size and the location of the precut service part.




1. Cut the replacement rail section to the appropriate length.



2. Fabricate a 'U' shaped reinforcement from 1.8 mm steel at least 100 mm in length to match the inside shape of the existing frame rail.



3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
4. Clean and prepare the mating surfaces.
5. Position the service part.
6. Check fit with 3-dimensional measuring equipment.
7. Plug weld the fabricated reinforcement between the rear rail and the rear rail section, ensuring an equal overlap of the reinforcement across the repair joint.



8. Butt weld the rear rail repair section to the trimmed rear rail.
9. Clean and prepare welded surfaces.

Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

10. Prime with 2-part catalyzed primer.
11. Apply sealers and anti-corrosion materials as necessary.
12. Install all related panels and components.
13. Install the fuel tank. Refer to Fuel Tank Replacement.