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 endgate. Refer to Endgate Replacement .
7. Remove the rear header trim. Refer to Roof Rear Header Panel Replacement .
8. Remove the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .
9. Remove the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement .
10. Remove the body tail lamp inner filler panel. Refer to Rear End Panel Filler Replacement .
11. 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 cargo area inner side panel brace to aid in installation.

12. Locate, mark and drill out the factory welds attaching the cargo area inner side panel brace to the cargo area inner side support bracket (1).
13. Locate, mark and drill out the factory welds attaching the cargo area inner side panel brace to body side panel assembly (1).
14. Remove the cargo area inner side panel brace and bracket from the vehicle.

### Installation Procedure

Important: The cargo area inner side panel brace and cargo area inner side panel bracket are one assembly and need to be separated before installation.

Important: Note the location of the factory welds and alignment of the cargo area inner side panel brace to cargo area inner side panel brace bracket to aid in installation.

1. Locate, mark and drill out the factory welds attaching the cargo area inner side panel brace to the cargo area inner side panel brace bracket (1).

Important: Locate the cargo area inner side panel brace bracket and the cargo area inner side panel brace to the vehicle before welding.

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).

2. Weld the cargo area inner side panel brace to the cargo area inner side panel bracket (1).

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.

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.

3. Align the datum holes (2).
4. Apply structural adhesive (3) to the body side assembly (1).
5. Weld the cargo area inner side panel brace assembly to the body side assembly (1).
6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
7. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
8. Install the body tail lamp inner filler panel. Refer to Rear End Panel Filler Replacement .
9. Install the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement .
10. Install the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .
11. Install the rear header trim. Refer to Roof Rear Header Panel Replacement .
12. Install the endgate. Refer to Endgate Replacement .
13. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
14. Install the rear header trim. Refer to Roof Rear Header Panel 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. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
18. Enable the SIR system. Refer to SIR Disabling and Enabling .