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 assemblies. 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 rear body rail cover. Refer to Pickup Box Cover Side Rail End Cover 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: Note the number and location of the factory welds for installation of the rear crossmember.

Important: The graphic is from underneath the vehicle looking rewards.

8. Locate, mark and drill out the spot welds in rear crossmember to the rear floor panel and subframe assemblies (1).

### 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 plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

1. Clean and prepare the mating surfaces of both parts of the panel.

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.

Important: Position the rear crossmember aligning the datum holes (1)

2. Weld the rear crossmember to the rear floor panel and subframe assembly (2).
3. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
4. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
5. Install the rear body rail cover. Refer to Pickup Box Cover Side Rail End Cover Replacement .
6. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
7. Install the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
8. Install the cargo liner. Refer to Cargo Box Liner Replacement .
9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
10. Enable the SIR system. Refer to SIR Disabling and Enabling .