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Laminated Steels - General Information and Specific Repair Procedures for Wheelhouse Replacement - Front, Extension Replacement Front Compartment Side Rail - Rear and Rail Replacement - Lower

Subject:Laminated Steels - General Information and Specific Repair Procedures for Wheelhouse Replacement - Front, Extension Replacement Front Compartment Side Rail-Rear and Rail Replacement - Lower

Models:2005 Buick LaCrosse, Allure (Canada Only)
2005 Pontiac Grand Prix



Laminated steel consists of three layers of material: two layers of mild steel with a layer of "visco-elastic" material between them. This "sandwich" of material layers provides better sound absorbing properties than regular, non-laminated materials.

Laminated steel is being used on the above listed vehicles to enhance the acoustic performance of these vehicles. Currently, the front dash panel of these vehicles is made from laminated steel.

This material is very different than standard steel applications. Because of these differences, it requires different repair procedures to be used when replacing components that attach directly to the laminated steel surfaces. Those components are typically structural rails, front wheelhouse/shock towers and front body hinge pillar inner panels. Depending on the design and build of the vehicle, though, some of the components may not attach directly to the laminated steel surface. Components that do not attach directly to the laminated steel surface may be attached in the normal manner.

General Repairability Guidelines

    • MIG welding of this material is not recommended due to contamination of the weld from the "visco-elastic" layer.
    • Rivet/bonding of components that attach to laminated steel surfaces is recommended. This process uses a structural rivet combined with metal panel bonding adhesives currently recommended by GM that meet the performance requirements of GM 6449G (guidelines for adhesive manufacturers to develop metal panel bonding adhesives).
    • Resistance spot welding is recommended where the plier or jaw openings and reach of the tool will allow. Refer to the GM Dealer Equipment Catalog for current recommendations of resistance spot welding equipment or call 1-800-GMTOOLS.
    • Laminated steel can be straightened cold or with heat. If heat is required, temperatures should be controlled to less than 1,200 degrees and the duration of the heat should be kept to less than 3 minutes overall (it is preferable that this be done in multiple steps). Heating this material following these guidelines will not effect the acoustical performance of this material.

Refer to GM Service Information for the above-listed vehicles for specific procedures related to the components that attach to laminated steels. The procedure below has recently been added to SI. Additional procedures are currently being developed and Service Manual Update bulletins will be published to inform dealers of this new information.

Wheelhouse Replacement-Front


Object Number: 1546664  Size: SH

Important: Model year 2004 and prior vehicles are not manufactured with laminated steel in front of the dashes. Therefore the front wheelhouse assembly can be MIG welded instead of the rivet and bonding process as stated in these instructions.

The front of the dash panel is formed from laminated steel. This steel is constructed by bonding 2 pieces of cold rolled steel (1) with a viscoelastic layer of adhesive (2). Metal inert gas (MIG) welding laminated steel does not meet GM Corporate standards for structural integrity. As an alternative, all factory welds will be replaced by using the rivet and adhesive bond method described in the installation portion of this procedure. The rivet and adhesive bond method must only be used in the areas as described in this procedure.

Important: Failure to follow this procedure will compromise the structural integrity of the vehicle.

Removal Procedure

    Caution:  Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

    Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  3. 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.

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

  7. Object Number: 1546678  Size: SH

    Important: Note the number and location of the factory welds for installation of the full wheelhouse service part.

  8. Remove the radiator support assembly. Refer to Radiator Support Replacement.
  9. Remove the upper fender rail. Refer to Rail Replacement - Upper.

  10. Object Number: 1546539  Size: SH

    Important: Drill through the wheelhouse flange only. Do NOT drill into the dash panel or the inner reinforcements.

  11. Using an 8-mm (5/16-in) spot weld remover, locate and drill out the factory welds on the weld flange connecting the wheelhouse to the dash panel.

  12. Object Number: 1546556  Size: SH
  13. Remove the wheelhouse.

Installation Procedure


    Object Number: 1546544  Size: SH
  1. Position the service wheelhouse to the vehicle using three-dimensional measuring equipment.
  2. Clamp the wheelhouse in place.

  3. Object Number: 1546580  Size: SH
  4. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the service wheelhouse and the dash panel in the exact locations as noted from the factory wheelhouse.

  5. Object Number: 1546556  Size: SH
  6. Remove the service wheelhouse.

  7. Object Number: 1546581  Size: SH

    Important: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1.5 in) apart.

  8. Drill 8-mm (5/16-in) plug weld holes in the service wheelhouse, as necessary, in the remaining locations noted from the original wheelhouse.
  9. Prepare the plug weld mating surfaces, as necessary.
  10. Apply 3M® Weld-Thru Coating, P/N 05913, or equivalent, to the plug weld mating surfaces.

  11. Object Number: 1546582  Size: SH
  12. Prepare the bond mating areas by grinding the body mating and the service part flanges to bare steel. Do NOT damage the corners or thin the metal during the grinding process.
  13. Clean the mating surfaces.

  14. Object Number: 1546583  Size: SH

    Important: The adhesive has a 40-50 minute working time. Do NOT allow the adhesive to cure prior to installing the service wheelhouse.

  15. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to both of the mating surfaces.

  16. Object Number: 1546584  Size: SH
  17. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare metal to ensure corrosion protection.

  18. Object Number: 1546585  Size: SH
  19. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to the mating surface of the service wheelhouse.

  20. Object Number: 1546544  Size: SH

    Important: Do NOT pull the wheelhouse off of the dash after adhesion. To align the parts, slide the wheelhouse against the front of the dash.

  21. Position the service wheelhouse to the vehicle using three-dimensional measuring equipment.
  22. Clamp the wheelhouse in place.

  23. Object Number: 1546586  Size: SH

    Important: Verify proper positioning of the service wheelhouse prior to riveting and welding.

  24. Install the 9 mm (11/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.
  25. Remove the excess adhesive from the wheelhouse area.

  26. Object Number: 1546587  Size: SH
  27. Plug weld the remaining holes accordingly.
  28. Clean and prepare all of the welded surfaces.
  29. Install the radiator support assembly. Refer to Radiator Support Replacement.
  30. Install the upper fender rail. Refer to Rail Replacement - Upper.
  31. Apply the sealers and anti-corrosion materials to the repaired area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
  32. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
  33. Install all of the related panels and components.
  34. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  35. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.

Extension Replacement Front Compartment Side Rail - Rear


Object Number: 1546664  Size: SH

Important: Model year 2004 and prior vehicles are not manufactured with laminated steel in front of the dashes. Therefore the front lower rail extension can be MIG welded instead of the rivet and bonding process as stated in these instructions.

The front of the dash panel is formed from laminated steel. This steel is constructed by bonding 2 pieces of cold rolled steel (1) with a viscoelastic layer of adhesive (2). Metal inert gas (MIG) welding laminated steel does not meet GM Corporate standards for structural integrity. As an alternative, all factory welds will be replaced by using the rivet and adhesive bond method described in the installation portion of this procedure. The rivet and adhesive bond method must only be used in the areas as described in this procedure.

Important: Failure to follow this procedure will compromise the structural integrity of the vehicle.

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

    Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  3. 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.

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

  7. Object Number: 1546512  Size: SH

    Important: Note the number and location of the factory welds for installation of the rail side extension service part.

    Important: Drill through the rail side extension flange only. Do NOT drill into the dash panel or the inner reinforcements.

  8. Using an 8-mm (5/16-in) spot weld remover, locate and drill out the factory welds on the weld flange connecting the lower rail side extension to the vehicle structure.

  9. Object Number: 1546513  Size: SH
  10. Remove the rail side extension.

Installation Procedure


    Object Number: 1546519  Size: SH
  1. Position the service rail side extension to the vehicle.
  2. Clamp the rail in place.

  3. Object Number: 1546522  Size: SH
  4. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the service rail side extension and the dash panel in the exact locations as noted from the factory rail side extension.

  5. Object Number: 1546513  Size: SH
  6. Remove the service rail side extension.
  7. Important: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1.5 in) apart.

  8. Drill 8-mm (5/16-in) plug weld holes in the service rail side extension, as necessary, in the remaining locations noted from the original rail side extension.
  9. Prepare the plug weld mating surfaces, as necessary.
  10. Apply 3M® Weld-Thru Coating, P/N 05913, or equivalent, to the plug weld mating surfaces.

  11. Object Number: 1546533  Size: SH
  12. Prepare the bond mating areas by grinding the body mating and the service part flanges to bare steel. Do NOT damage the corners or thin the metal during the grinding process.
  13. Clean the mating surfaces.

  14. Object Number: 1546534  Size: SH

    Important: The adhesive has a 40-50 minute working time. Do NOT allow the adhesive to cure prior to installing the service rail side extension.

  15. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to both of the mating surfaces.

  16. Object Number: 1546538  Size: SH
  17. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare metal to ensure corrosion protection.

  18. Object Number: 1546588  Size: SH
  19. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to the mating surface of the service rail side extension.

  20. Object Number: 1546519  Size: SH

    Important: Do NOT pull the service rail side extension off of the dash after adhesion. To align the parts, slide the service rail side extension against the front of the dash.

  21. Position the service rail side extension to the vehicle using three-dimensional measuring equipment.
  22. Clamp the service rail side extension in place.

  23. Object Number: 1546546  Size: SH

    Important: Verify proper positioning of the service rail side extension prior to riveting and welding.

  24. Install the 9 mm (11/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.

  25. Object Number: 1546548  Size: SH
  26. Install the 14 mm (17/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.
  27. Remove the excess adhesive from the service rail side extension area.

  28. Object Number: 1546552  Size: SH
  29. Plug weld the remaining holes accordingly.
  30. Clean and prepare all of the welded surfaces.
  31. Apply the sealers and anti-corrosion materials to the repaired area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
  32. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
  33. Install all of the related panels and components.
  34. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  35. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.

Rail Replacement - Lower


Object Number: 1546664  Size: SH

Important: Model year 2004 and prior vehicles are not manufactured with laminated steel in front of the dashes. Therefore the front lower rail can be MIG welded instead of the rivet and bonding process as stated in these instructions.

The front of the dash panel is formed from laminated steel. This steel is constructed by bonding 2 pieces of cold rolled steel (1) with a viscoelastic layer of adhesive (2). Metal inert gas (MIG) welding laminated steel does not meet GM Corporate standards for structural integrity. As an alternative, all factory welds will be replaced by using the rivet and adhesive bond method described in the installation portion of this procedure. The rivet and adhesive bond method must only be used in the areas as described in this procedure.

Important: Failure to follow this procedure will compromise the structural integrity of the vehicle.

Removal Procedure

    Caution: Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices.

    Caution: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  3. 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.

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

  7. Object Number: 1547428  Size: SH

    Important: Note the number and location of the factory welds for installation of the full rail service part.

  8. Remove the front wheelhouse assembly. Refer to Wheelhouse Replacement - Front.
  9. Remove the radiator support assembly. Refer to Rail Replacement - Upper.
  10. Remove the front rail side extension. Refer to Extension Replacement Front Compartment Side Rail - Rear.

  11. Object Number: 1547430  Size: SH

    Important: Drill through the rail flange only. Do NOT drill into the dash panel or the inner reinforcements.

  12. Using an 8-mm (5/16-in) spot weld remover, locate and drill out the factory welds on the weld flange connecting the lower rail to the dash panel.

  13. Object Number: 1547431  Size: SH
  14. From the passenger compartment, locate and drill out the remaining factory weld.

  15. Object Number: 1547432  Size: SH
  16. Remove the full rail.

Installation Procedure


    Object Number: 1550592  Size: SH

    Important: Failure to install the front compartment lower rail reinforcement to the front compartment lower rail will compromise the structural integrity of the vehicle.

  1. Drill 8-mm (5/16-in) plug weld holes in the service front lower rail reinforcement in the location noted from the original rail.
  2. Prepare the plug weld mating surfaces, as necessary.
  3. Apply 3M® Weld-Thru Coating, P/N 05913, or equivalent, to the plug weld mating surfaces.
  4. Position the front lower rail reinforcement.

  5. Object Number: 1550591  Size: SH
  6. Plug weld the holes accordingly.

  7. Object Number: 1547434  Size: SH
  8. Position the service rail to the vehicle using three-dimensional measuring equipment.
  9. Clamp the rail in place.

  10. Object Number: 1547435  Size: SH
  11. Using a 7-mm (17/64-in) bit, drill the rivet attachment holes through the service rail and the dash panel in the exact locations as noted from the factory rail.

  12. Object Number: 1547432  Size: SH

    Important: If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1.5 in) apart.

  13. Remove the service rail.
  14. Prepare the plug weld mating surfaces, as necessary.
  15. Apply 3M® Weld-Thru Coating, P/N 05913, or equivalent, to the plug weld mating surfaces.

  16. Object Number: 1547436  Size: SH
  17. Prepare the bond mating areas by grinding the body mating and the service part flanges to bare steel. Do NOT damage the corners or thin the metal during the grinding process.

  18. Object Number: 1546548  Size: SH

    Important: Do NOT allow the adhesive to cure prior to installation of the front rail side extension. Refer to Extension Replacement Front Compartment Side Rail - Rear.

    Important: Note the necessary location for installation of a 14-mm (17/32-in) long rivet.

  19. Clean the mating surfaces.

  20. Object Number: 1547438  Size: SH

    Important: The adhesive has a 40-50 minute working time. Do NOT allow the adhesive to cure prior to installing the service rail.

  21. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to both of the mating surfaces.

  22. Object Number: 1547443  Size: SH
  23. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare metal to ensure corrosion protection.

  24. Object Number: 1547445  Size: SH
  25. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive, GM P/N 12378567 (Canadian P/N 88901675), or equivalent, to the mating surface of the service rail.

  26. Object Number: 1547434  Size: SH

    Important: Do NOT pull the rail off of the dash after adhesion. To align the parts, slide the rail against the front of the dash.

  27. Position the service rail to the vehicle using three-dimensional measuring equipment.
  28. Clamp the rail in place.

  29. Object Number: 1547453  Size: SH

    Important: Verify proper positioning of the service rail prior to riveting and welding.

  30. Install the 9 mm (11/32 in) long rivets so that the rivet head contacts the passenger compartment side of the dash.

  31. Object Number: 1547455  Size: SH
  32. Install the 14-mm (17/32-in) long rivet so that the rivet head contacts the passenger compartment side of the dash, extending through the front rail and through the rail side extension.
  33. Remove the excess adhesive from the rail area.

  34. Object Number: 1551128  Size: SH
  35. Plug weld the remaining holes accordingly.
  36. Clean and prepare all of the welded surfaces.
  37. Install the front wheelhouse assembly. Refer to Wheelhouse Replacement - Front.
  38. Install the front rail side extension. Refer to Extension Replacement Front Compartment Side Rail - Rear.
  39. Install the radiator support assembly. Refer to Rail Replacement - Upper.
  40. Apply the sealers and anti-corrosion materials to the repaired area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
  41. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
  42. Install all of the related panels and components.
  43. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  44. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.

Parts Information

Important:  These kits contain a panel or rail, an instruction sheet and rivets. The rivets and instruction sheet are common among the kits, but the panel or rail is specific to each kit.

Part Number

Description

89025134

Panel Kit, Frt W/H (LH)

89025136

Panel Kit, Frt W/H (RH)

89025137

Rail Kit, F/Cmpt Si (LH Light)

89025139

Rail Kit, F/Cmpt Si (LH Heavy)

89025140

Rail Kit, F/Cmpt Si (RH Light)

89025141

Rail Kit, F/Cmpt Si (RH Heavy)

89025776

Rail Kit, F/Cmpt Si (RH Otr Ext)

89025774

Rail Kit, F/Cmpt Si (LH Otr Ext)

12378567 (US)

88901675 (Canada)

Metal Panel Bonding Adhesive*

* You can also use LORD FUSOR P/N 108B/109B. To order, contact them at 1-800-458-0456 or at www.fusor.com.

Parts are expected to be available from GMSPO.