For 1990-2009 cars

### Removal Procedure

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

Caution: Refer to Safety Glasses Caution in the Preface section.

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

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the cargo liner. Refer to Cargo Box Liner Replacement .
4. Remove the tail lamp assembly. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
5. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
6. Remove the endgate. Refer to Endgate Replacement .
7. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: The note the location of the factory welds and alignment of the tail lamp filler panel to aid in installation.

8. Locate, mark and drill out the spot welds attaching the tail lamp filler panel to rear quarter panel and rear floor panel (1).
9. Remove the tail lamp filler panel from the vehicle.

### Installation procedure

Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.

Important: If the location of the original spot weld holes cannot be determined, or if structural weld-thru adhesive is present, space the puddle weld holes every 32 mm (1¼ in).

Important: Follow the adhesive manufacturer's instructions during the assembly process. Heat must be applied as per the manufacturer's specifications to cure the adhesives and to expand the sealing baffles.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when disassembling.
2. Clean and prepare the mating surfaces of both parts of the body side panel assembly.

Important: Secondary sealer must be applied to the perimeter of all flanges. Secondary sealer must be applied to all welds/joints that where originally covered by secondary sealer.

3. Apply the primary sealer to the tail lamp filler panel.
4. Weld the tail lamp filler panel to the rear quarter panel and rear floor panel (1).
5. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
6. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
7. Install the endgate. Refer to Endgate Replacement .
8. Install the tail lamp assembly. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
9. Install the cargo liner. Refer to Cargo Box Liner Replacement .
10. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
12. Enable the SIR system. Refer to SIR Disabling and Enabling .