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 rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
4. Remove the cargo liner. Refer to Cargo Box Liner Replacement .
5. Remove the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
6. Remove the fuel tank. Refer to Fuel Tank Replacement .
7. Remove the child restraint tether anchor. Refer to Child Restraint Tether Anchor Replacement .
8. Remove the front seats. Refer to Front Seat Replacement - Bucket .
9. Remove the front seat belts. Refer to Front Seat Belt Replacement .
10. Remove the headliner. Refer to Headlining Trim Panel Replacement .
11. Remove the battery. Refer to Battery Replacement .
12. Remove the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement .
13. Remove the remote function actuator. Refer to Remote Control Door Lock Receiver and Theft Deterrent Module Replacement .
14. Remove the positive battery cable from the vehicle. Refer to Battery Positive Cable Replacement .
15. Remove the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement .
16. Remove the soft tonneau cover bracket. Refer to Pickup Box Cover Crossmember Bracket Replacement .
17. Remove the rear window. Refer to Rear Window Replacement .
18. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
19. Remove the rear header trim. Refer to Roof Panel Rear Applique Replacement .
20. Remove the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .

Important: Note the number and location of the factory welds for installation of the rear window panel reinforcement.

21. Locate, mark and drill out the spot welds in the rear window panel reinforcement (1) to the rear window panel (2).

### Installation Procedure

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

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

Important: Position the rear window panel reinforcement in the central position, noting the location of the original weld points.

2. Weld the rear window panel reinforcement (1) to the rear window panel (2).
3. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
4. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
5. Install the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement .
6. Install the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .
7. Install the rear header trim. Refer to Roof Panel Rear Applique Replacement .
8. Install the soft tonneau cover bracket. Refer to Pickup Box Cover Crossmember Bracket Replacement .
9. Install the positive battery cable to the vehicle. Refer to Battery Positive Cable Replacement .
10. Install the remote function actuator. Refer to Remote Control Door Lock Receiver and Theft Deterrent Module Replacement .
11. Install the headliner. Refer to Headlining Trim Panel Replacement .
12. Install the front seats. Refer to Front Seat Replacement - Bucket .
13. Install the front seat belts. Refer to Front Seat Belt Replacement .
14. Install the child restraint tether anchor. Refer to Child Restraint Tether Anchor Replacement .
15. Install the tail lamp assemblies. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement .
16. Install the cargo liner. Refer to Cargo Box Liner Replacement .
17. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
18. Install the fuel tank. Refer to Fuel Tank Replacement .
19. Install the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement .
20. Install the battery. Refer to Battery Replacement .
21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
22. Enable the SIR system. Refer to SIR Disabling and Enabling .