For 1990-2009 cars

### Removal Procedure

1. Remove all related panels and components.
2. Visually inspect and restore as much of the damage as possible to factory specifications.
3. Remove the following as necessary:

• | Sealers

• | Sound deadeners

• | Anti-corrosion materials

4. Use an air chisel to remove the rear engine mount.
5. Locate and drill out resistance welds in the torque box panel. Drill through one layer of metal ONLY.
6. Locate welds that secure the rail to the floor pan from the underside of the vehicle.
7. Use a 3 mm (1/8 in) drill bit to drill through the floor and mark welds for removal.
8. Separate the floor pan reinforcement vertical flange from inside the lower rail. Care must be taken to not damage the flange.
9. Drill out factory welds along the lower flange on the floor pan reinforcement and at the wheelhouse. Note that the flanges overlap the rail.
10. From inside of vehicle, use an 8 mm (5/16 in) drill bit to drill through the floor pan and the reinforcement inside the vehicle.
11. Remove the damaged rail.

### Installation Procedure

1. Prepare mating surfaces and check for proper fit of the new rail.
2. Apply suitable weld-through primer.
3. Position the new rail in place and check for proper alignment. Use 3-dimensional measuring.
4. With the new rail in place, plug weld all holes created from the removal process.
5. Where the floor inner panel does not contact the floor pan, use a ball pein hammer to flatten the inner panel against the floor pan.
6. Plug weld floor to new rail in remaining areas.
7. Clean and prepare welded surfaces.

Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

8. Apply approved anti-corrosion primer.
9. Apply sealers and refinish as necessary.
10. Install all related panels and components.