For 1990-2009 cars

### Removal Procedure

Caution: Refer to Approved Equipment for Collision Repair 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 .

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

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

3. Remove the cargo liner. Refer to Cargo Box Liner Replacement .
4. Remove the front doors. Refer to Front Side Door Replacement .
5. Remove the front seats. Refer to Front Seat Replacement - Bucket .
6. Remove the front seat belts. Refer to Front Seat Belt Replacement .
7. Remove the headliner. Refer to Headlining Trim Panel Replacement .
8. Remove the remote function actuator. Refer to Remote Control Door Lock Receiver and Theft Deterrent Module Replacement .
9. Remove the positive cable from the vehicle. Refer to Battery Positive Cable Replacement .
10. Remove the rear header trim. Refer to Roof Rear Header Panel Replacement .
11. Remove the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .
12. Remove the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement .
13. Remove the load floor support panel. Refer to Load Floor Panel Assembly Replacement .
14. Remove the soft tonneau cover bracket. Refer to Pickup Box Cover Crossmember Bracket Replacement .
15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
16. Remove the fuel tank. Refer to Fuel Tank Replacement .
17. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
18. Locate, mark and drill out the factory welds (1) attaching the rear seat panel to 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).

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 and over all joints.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when dissembling.
2. Clean and prepare the mating surfaces of all weld and flange joints.

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

3. Apply an approved structural adhesive to the rear seat panel (1).
4. Weld the rear seat panel to the vehicle (1).

Important: All joints and welds must be checked for water leaks before the vehicle is fully reassembled.

5. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
6. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
7. Install the fuel tank. Refer to Fuel Tank Replacement .
8. Install the soft tonneau cover bracket. Refer to Pickup Box Cover Crossmember Bracket Replacement .
9. Install the body lock pillar trim. Refer to Body Lock Pillar Applique Replacement .
10. Install the load floor support panel. Refer to Load Floor Panel Assembly Replacement .
11. Install the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement .
12. Install the rear header trim. Refer to Roof Rear Header Panel Replacement .
13. Install the positive cable to the vehicle. Refer to Battery Positive Cable Replacement .
14. Install the remote function actuator. Refer to Remote Control Door Lock Receiver and Theft Deterrent Module Replacement .
15. Install the headliner. Refer to Headlining Trim Panel Replacement .
16. Install the front seat belts. Refer to Front Seat Belt Replacement .
17. Install the front seats. Refer to Front Seat Replacement - Bucket .
18. Install the front doors. Refer to Front Side Door Replacement .
19. Install the cargo liner. Refer to Cargo Box Liner Replacement .
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
21. Enable the SIR system. Refer to SIR Disabling and Enabling .
22. If re-programming is required. Refer to Control Module References .