Trunk / Liftgate: Service and Repair

Rear End Panel Replacement

Removal Procedure

Caution: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection , earplugs, welding gloves, and protective clothing.

Important: This panel is replaced at factory seams.

1. Disable the SIR system. Refer to SIR Disabling and Enabling Service and Repair.
2. Disconnect the negative battery cable.






Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

3. Remove all related panels and components.
4. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

Important: Note the number and location of the factory welds for installation of the rear end panel.






6. Locate, mark, and drill out all the necessary factory welds.






7. Remove the rear end panel.

Installation Procedure






Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 40 mm (1 1/2 in).

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.






4. Position the rear end panel.






5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems Technician Safety Information.
10. Connect the negative battery cable.
11. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR Service and Repair.