For 1990-2009 cars

# Repair Procedure for Stripped or Detached Front Seat to Floor Panel Attachments

Subject: | Repair Procedure for Stripped or Detached Front Seat to Floor Panel Attachments (Use Repair Bolt or Replace Floor Panel Weld Nut)

Models: | All 1991 -- 1999 Saturn S-Series vehicles

### Condition

The weld nut(s) may strip or detach during removal or installation of front seat to floor pan anchor bolts.

### Cause

Stripped or detached front seat attachment weld nuts may be caused by improper installation of front seat attachment bolts during removal and installation.

### Correction

• | If weld nut is stripped, replace with a self-tapping oversized bolt. (Refer to "Striped Threads in Weld Nut" procedure in this bulletin.)

• | If front seat attachment bolt is broken off in weld nut, remove broken front seat attachment bolt. (Refer to "Broken Bolt Weld Nut" procedure in this bulletin.)

• | If weld nut is detached, remove and replace weld nut. (Refer to "Detached Weld Nut in Floor Pan" procedure in this bulletin.)

### Procedure

STRIPPED THREADS IN WELD NUT

If front seat anchor bolt(s) will not accept a torque of 30 N·m (22 lb ft) when installing front seat(s), use the following procedure.

1. Measure thread diameter of original bolt in a non-stripped area of bolt.

• | A 8 mm (0.31 in), thread diameter measurement indicates the original production (P/N 21047085) was used.

• | A 9 mm (0.35 in), thread diameter measurement indicates production repair bolt was used.

2. If bolt thread diameter measurement is 8 mm (0.31 in), obtain 9 mm (0.35 in) repair bolt (P/N 21035568) that will rethread weld nut. If bolt thread diameter measurement is 9 mm (0.35 in), contact Saturn Technical Assistance.

BROKEN BOLT IN WELD NUT

If front seat to floor panel attachment bolt(s) have broke off in weld nut during the process of removing or installing front seat(s), use the following procedure

1. With front seats removed from vehicle, remove carpet. (Refer to "Carpet -- All" removal procedure in the appropriate model year Body/Repair service manual.)

Important: After broken front seat attachment bolt is removed, threads in weld nut DO NOT require re-threading. Repair bolt will cut new threads.

2. Use a center-punch to mark the center of broken front seat attachment bolts and drill a 4 mm (5/32in) pilot hole in center of broken bolt.
3. Use a #3 Easy-Out extractor or equivalent and remove remainder of broken seat attachment bolt.
4. Install carpet. Refer to "Carpet -- All" installation procedure in the appropriate model year Body/Repair service manual.)
5. Obtain 9 mm (0.35 in.) repair bolt (P/N 21035568) that will rethread weld nut and install front seats

Tighten
Tighten the nut to 30 N·m(22 lb ft).

6. Function front seats to full forward and full rearward positions to ensure proper operation.

DETACHED WELD NUT IN FLOOR PAN

If front seat to floor panel attachment weld nut(s) have detached from floor panel, use one of the following three procedures according to which weld nut(s) have detached.

Front - Inner and Outer Weld Nuts

1. With front seats removed from vehicle, remove carpet. (Refer to "Carpet -- All" removal procedure in the appropriate model year Body/Repair service manual.)
2. Remove fuel door and decklid/liftgate release able from floor pan #2 bar assembly, if necessary.
3. Use a magnetic retrieval tool to remove original weld nut from inside the floor pan #2 bar assembly, if it is loose and laying in #2 bar assembly.
4. Obtain replacement 31 mm (1.22 in.) weld nut (P/N 21122052) that is unthreaded and can be used with standard front seat attachment bolt (P/N 21047085).

Important: Do not use a tap and die set to cut threads in unthreaded replacement 31 mm (1.22 in.) weld nut. Front seat attachment bolt (P/N 21047085) will be used to cut threads.

5. Place unthreaded replacement 31 mm (1.22 in.) weld nut (P/N 21122052) on a bench vise.

• | Use a standard front seat attachment bolt (P/N 21047085) to cut threads in weld nut.

• | Grind weld projection tips from weld nut.

6. Grind ELPO coating from area surrounding weld nut on vehicle floor pan.
7. Drill three 8 mm (5/16 in.) holes in the #2 bar assembly. these three holes will surround the hole where the weld nut will be attached. Use the illustration as a guide to drill holes.
8. Route a flexible wire into the center of hole where replacement weld nut will be attached to #2 bar assembly. Route wire through #2 bar assembly and out of access hole near rocker panel, (right side similar)
9. Once wire is through access hole, place end of wire through replacement 31 mm (1.22 in.) weld nut (P/N 21122052). Place several loops in wire in order for the wire to hold the weld nut. Do not wrap the wire around the weld nut.
10. Pull weld nut back through access hole and line weld nut up with hole where it will be attached.
11. Using a MIG welder, plug weld replacement weld nut to the #2 bar assembly in the three holes that were previously drilled.
12. Remove wire from #2 bar assembly and weld nut.
13. Grind welds flush.
14. Prime and paint welded area. (Refer to " Body Paint" in the appropriate model year Body/Collision service manual.)
15. Install fuel door and decklid/liftgate release cable to floor pan #2 bar assembly.
16. Install carpet. (Refer to "Carpet -- All" installation procedure in the appropriate model year Body/Repair service manual.)
17. Apply Loctite 242® Threadlocker, or equivalent, to front seat attachment bolts and install front seats.

Tighten
Tighten the bolt to 30 N·m (22 lb ft).

18. Function front seats to full forward and full rearwards positions to ensure proper operation.

Rear - Inner Weld Nut

1. With front seats removed from vehicle, remove carpet. (Refer to "Carpet -- All" removal procedure in the appropriate model year Body/Repair service manual.)
2. Use a magnetic retrieval tool to remove original weld nut from inside the floor pan #3 bar assembly, if it loose and laying inside #3 bar assembly.
3. Obtain replacement 25 mm (0.98 in.) weld nut (P/N 20381222) that is threaded and can be used with standard front seat attachment bolt (P/N 21047085).
4. Grind weld projection tips from replacement 25 mm (0.98 in.) threaded weld nut.
5. Grind ELPO coating from area surrounding weld nut on vehicle floor pan.
6. Drill three 8 mm (5/16 in.) holes in the #3 bar assembly. these three holes will surround the hole where the weld nut will be attached. Use the illustration as a guide to drill holes.

6.1. | Hole in bar assembly that seat attachment bolts pass through

6.2. | Hole positions that need to be drilled for plug welds

7. Locate access hole in the #3 bar assembly as shown in the illustration, (right side shown, left side similar). This hole will need to be made slightly longer in order to pass the replacement weld nut through. This hole enlargement will not need to be repaired, except for the ELPO primer.
8. Route a flexible wire into the center of hole where replacement weld nut will be attached to #3 bar assembly. Route wire through #3 bar assembly and out of access hole.
9. Once wire is through access hole, place end of wire through access hole, place end of wire through 25 mm (0.98 in.) replacement weld nut. Place several loops in wire in order for the wire to hold the weld nut. Do not wrap the wire around the weld nut.
10. Pull weld nut back through access hole and line weld nut up with hole where it will be attached.
11. Using a MIG welder, plug weld nut to the #3 bar assembly in the three holes that were previously drilled.
12. Remove wire from #3 bar assembly and weld nut
13. Grind welds flush.
14. Prime and paint welded area. (Refer to "Body Paint" in the appropriate model year Body/Collision service manual.)
15. Install carpet. (Refer to "Carpet -- All" installation procedure in the appropriate model year Body/Repair service manual.)
16. Apply Loctite 242® Threadlocker, or equivalent, to front seat attachment bolts and install front seats.

Tighten
Tighten bolts to 30 N·m (22 lb ft)

17. Function front seats to full forward and full rearward position to ensure proper operation.

Rear - Outer Weld Nut

1. With front seats removed from vehicle, remove carpet. (Refer to "Carpet -- All" removal procedure in the appropriate mode year Body/Repair service manual.)
2. Use a magnetic retrieval tool to remove original weld nut from inside the floor pan #3 bar assembly if it is loose and laying inside #3 bar assembly.
3. Obtain replacement 25 mm (0.98 in.) weld nut (P/N 20381222) that is threaded and can be used with standard front seat attachment bolt (P/N 21047085).
4. Grind weld projection tips form replacement 25 mm (0.98) threaded weld nut.
5. Grind ELPO coating from area surrounding weld nut on vehicle floor pan.
6. Drill three 8 mm (5/16 in.) holes in the #3 bar assembly. These three holes will surround the hole where the weld nut will be attached. Use the illustration as a guide to drill holes.

6.1. | Hole in bar assembly that seat attachment bolts pass through

6.2. | Hole positions that need to be drilled for plug welds

7. Route a flexible wire into the center of hole where replacement weld nut will be attached to #3 bar assembly. Route wire through #3 bar assembly and out of gap between floor pan and rear out-board side of #3 bar assembly, (right side shown, left side similar).
8. Once wire is through access hole, place end of wire through 25 mm (0.98 in) replacement weld nut. Place several loops in wire in order for the wire to hold the weld nut. Do not wrap the wire around the weld nut.
9. Pull weld nut back through gap and line weld nut up with hole where it will be attached.
10. Using a MIG welder, plug weld replacement weld nut to the #3 bar assembly in the three holes that were previously drilled.
11. Remove wire from #3 bar assembly.
12. Grind welds flush.
13. Prime and paint welded area. (Refer to "Body Paint" in the appropriate model year Body /Collision service manual.)
14. Install carpet. (Refer to "Carpet -- All" installation procedure in the appropriate mode year Body/repair service manual.)
15. Apply Loctite 242® Threadlocker, or equivalent, to front seat attachment bolts and install front seats.

Tighten
Tighten bolts to 30 N·m (22 lb ft).

16. Function front seats to full forward and full rearward positions to ensure proper operation.

#### Parts Requirements

21047085 | Standard Front Seat Attachment Bolt
21035568 | 9 mm (0.35 Repair Bolt
21122052 | 31 mm (1.22 in.) Unthreaded Weld Nut
20381222 | 25 mm (0.98 in.) Threaded Weld Nut
21485277 | Locktite 242® Threadlocker

### Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

Case Type | Description | Labor Operation Code | Time
--- | --- | --- | ---
VW | Front Seat Weld Nut Replacement | Z4025 | 1.0 hrs.
Add | To replace each additional weld nut | -- | 0.6 hrs
VW | Broken Front Seat Attachment Bolt Removal | Z4026 | 0.3 hrs

Important: Installation of front seats require the use of Locktite 242® Threadlocker (P/N 21485277). Claims received in the amount of Retailer cost plus 30% for this part will be accepted. It will be necessary to sell this part to the CSO as and "OT" (other than) part. Claims exceeding the cost equivalent of an 1/8 of a bottle will be returned with return reason 064 - Parts Amount Excessive.