GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2006 🢒 GTO 🢒 Preface 🢒 Cautions and Notices 🢒 Upper Rail Replacement

Removal Procedure

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

    Important: When replacing panels that involve servicing of stationary window, refer to Windshield Replacement in Stationary Windows.

  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. Object Number: 1370251 Size: SH
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .

    5. Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

  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/Coatings.

    6. Object Number: 1370255 Size: SH

    Important: Do not damage any inner panels or reinforcements.

  6. Locate and drill out all factory welds. Note the number and location of welds for installation of the front upper rail.

    7. Object Number: 1370289 Size: SH
  7. Remove the damaged front upper rail.

Installation Procedure

    Object Number: 1370346 Size: SH

    Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1½ in) apart.

  1. Drill 8-mm (5/16-in) plug weld holes, as necessary, in locations noted from the original front upper rail.
  2. Prepare all mating surfaces as necessary.
  3. Apply 3M® Weld-Thru coating P/N 05916, or equivalent ,to all mating surfaces.

    4. Object Number: 1370304 Size: SH
  4. Position the upper rail.

    5. Object Number: 1370364 Size: SH
  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/Coatings.
  8. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint/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.