Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Remove the front impact bar. Refer to Front Bumper Impact Bar Replacement.
5. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.
6. Restore as much of the damage as possible to the factory specifications. Refer to Dimensions - Body.

Warning: Refer to Collision Sectioning Warning in the Preface section.




7. Determine the sectioning joint location from the center of the rear upper radiator support bolt (1)



8. Measure 67 mm (2 5/8 in) (a) forward from the center of the rear upper radiator support bolt.



9. Mark the top of the frame rail at the sectioning location.
10. At the mark align a sliding square or similar tool (1) square to surface to the vertical walls of the frame rail.
11. Scribe a line to both sides of the frame rail.



12. Apply masking tape (1) to the scribe line completely around the frame rail.



13. Cut the frame rail at the rear edge of the tape line using a reciprocating saw or equivalent tool (1).



14. Remove the damaged frame rail end section (1).

1. Grind the existing frame rail seam to taper the seam at a 45-degree angle.
2. Clean and prepare all of the welded mating surfaces.
3. Apply 3M weld-thru coating P/N 05916 or equivalent as necessary to all bare metal surfaces.



4. Position the service frame section (1) to the existing frame.



5. Maintain a gap of one and one half frame rail metal thickness at the sectioning joint (1) and clamp in place.
6. Inspect the frame measurements three-dimensional to ensure proper position of the service frame.



7. Using a metal inert gas (MIG) welder (1), continuous-weld the upper and lower horizontal joints from corner to corner.
8. Using a MIG welder, continuous-weld the upper and lower vertical joints from corner to corner.
9. Install the front impact bar. Refer to Front Bumper Impact Bar Replacement.
10. Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair.

Note: DO NOT top coat any bonding surface. Use primer only on bonding surfaces. Refer to adhesive manufacturer's recommendations.

11. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
14. Enable the SIR system. Refer to SIR Disabling and Enabling.