For 1990-2009 cars

### Removal Procedure

Caution: Refer to Approved Equipment for Collision Repair 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 .

Caution: Refer to Vehicle Lifting Caution in the Preface section.

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

4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
6. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
7. Remove the endgate. Refer to Endgate Adjustment .
8. Remove the rear muffler assembly. Refer to Exhaust Muffler Replacement - Left Side and/or Exhaust Muffler Replacement - Right Side .
9. Remove the rear muffler hanger bracket. Refer to Exhaust Hanger Mounting Bracket Replacement .
10. Remove the rear floor. Refer to Rear Floor Panel Replacement .
11. Remove the spare wheel support carrier. Refer to Spare Wheel Hoist Reinforcement .
12. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
13. Locate, mark and drill out the factory welds attaching the rear rail to the vehicle welds (1).
14. Remove the appropriate rail section 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 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. Prepare the mating surfaces, as necessary.
2. Apply 3M Weld-Thru Coating or equivalent to all mating surfaces.
3. Align the rear rail extension using the datum points on the vehicle and using the locations marked during removal (1).

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.

4. Weld the rear rail to the vehicle (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 rear floor. Refer to Rear Floor Panel Replacement .
8. Install the spare wheel support carrier. Refer to Spare Wheel Hoist Reinforcement .
9. Install the rear muffler hanger bracket. Refer to Exhaust Hanger Mounting Bracket Replacement .
10. Install the rear muffler assembly. Refer to Exhaust Muffler Replacement - Left Side and/or Exhaust Muffler Replacement - Right Side .
11. Install the endgate. Refer to Endgate Adjustment .
12. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
13. Install the rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
14. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
15. Install the cargo liner. Refer to Cargo Box Liner Replacement .
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
17. Enable the SIR system. Refer to SIR Disabling and Enabling .