For 1990-2009 cars only
Removal Procedure
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Remove all related panels and components.
- Restore as much of the damage as possible to factory specifications.
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Perform the necessary procedures to gain access to the repair.
- Locate and drill out all factory welds. Note the number and location of welds for installation of the front upper rail.
- Cut along the rear of the front upper rail (1) as shown.
- Remove the damaged front upper rail.
Caution: Refer to Foam Sound Deadeners Caution in the Preface section.
Important: Do not damage any inner panels or reinforcements.
Installation Procedure
- Drill 8 mm (5/16) in plug weld holes as necessary in locations noted from the original front upper rail.
- Prepare all attachment surfaces as necessary.
- Apply 3M Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.
- Position the upper rail.
- Plug weld accordingly.
- Stitch weld along the entire rear of the front upper rail (1).
- Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
- Go back and complete the stitch weld to create a solid weld joint with minimal heat distortion.
- Clean and prepare all welded surfaces.
- Complete the necessary procedures.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
- Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .
- Install all related panels and components.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
Important: In any area damaged beyond recognition, space plug weld holes every 40 mm (1 in) apart.
