GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2006 🢒 GTO 🢒 Body 🢒 Collision Repair 🢒 Floor Pan Assembly

Removal Procedure

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


    Object Number: 1380492 Size: SH
  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 the fuel tank. Refer to Fuel Tank Replacement in Engine Controls.
  4. Remove all related panels and components.
  5. Repair as much of the damage as possible to factory specifications.
  6. 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/Coatings.

    7. Object Number: 1380516 Size: SH
  7. Locate, mark, and drill out all factory welds attaching the rear end panel assembly to the tail lamp housing, rear quarter panel and quarter panel lower extension.

    8. Object Number: 1380523 Size: SH
  8. Locate, mark, and drill out all factory welds attaching the left rear quarter panel to the left quarter panel inner assembly and the left rear compartment floor panel outer extension.

    9. Object Number: 1380525 Size: SH
  9. Locate, mark, and drill out all factory welds attaching the right rear quarter panel to the right quarter panel inner assembly and the right rear compartment floor panel outer extension.

    10. Object Number: 1380527 Size: SH
  10. Locate, mark, and drill out all factory welds attaching the left rear inner wheelhouse panel assembly to the rear floor panel assembly and rear compartment floor panel assembly.

    11. Object Number: 1380528 Size: SH
  11. Locate, mark, and drill out all factory welds attaching the right rear inner wheelhouse panel assembly to the rear floor panel assembly and rear compartment floor panel assembly.

    12. Object Number: 1380530 Size: SH
  12. Locate, mark, and drill out all factory welds attaching the rear floor panel assembly to the rear window panel assembly and the rear seat back panel extension assembly.

    13. Object Number: 1380532 Size: SH
  13. Locate, mark, and drill out all factory welds attaching the rear floor panel outer extension to the inner rocker panel.

    14. Object Number: 1380533 Size: SH
  14. Locate, mark, and drill out all factory welds attaching the park brake cable bracket to the rear floor panel assembly.

    15. Object Number: 1380534 Size: SH
  15. Locate, mark, and drill out all factory welds attaching the front floor panel assembly (3) and the rear floor panel assembly (2).
  16. Locate, mark, and drill out all factory welds attaching the rear floor panel assembly to the inner rocker panel (1) on each side.
  17. Locate, mark and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
  18. Remove the damaged rear rail underbody assembly.

Installation Procedure

    Object Number: 1380492 Size: SH
  1. Clean and prepare the mating surfaces.
  2. Verify for proper fit of the rear rail underbody assembly.
  3. Drill 8-mm (5/16-in) plug weld holes on the service assembly, as necessary, in the locations noted from the original assembly.
  4. Apply 3M® Weld-Thru coating P/N 05916, or equivalent, to all mating surfaces.
  5. Position the service assembly.
  6. Verify the fit with 3 dimensional measuring equipment. Refer to Dimensions - Body .
  7. Plug weld accordingly with frequent measurements to ensure proper fit.
  8. Clean and prepare all welded surfaces.
  9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
  10. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
  11. Install all related panels and components.
  12. Install the fuel tank. Refer to Fuel Tank Replacement in Engine Controls.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  14. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.