Body Rear End Panel Replacement Bond-On

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

Important: This adhesive bonding procedure repreents one manufacturer's installation application. Other manufacturers' procedures may vary, including MIG welding in some areas of the repair. Always follow the system manufacturer's instructions for application, handling, and curing.

Important: Before beginning the repair, refer to Metal Panel Bonding for proper adhesive preparations and general information.

1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove all related panels and components.
4. Repair as much of the damage as possible. Refer to Dimensions - Body .
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.




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

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



7. Remove the rear end panel.

1. Grind the surface of the body mating flanges to bare steel.
2. Grind the body rear end panel mating flanges to remove the E-coating. Take care not to damage the corners or thin the metal during the grinding operation.
3. Clean the mating surfaces.

Important: The adhesive has a working time of 40-50 minutes. Do not allow the adhesive to totally cure off the vehicle, as proper alignment of the panel to the body will be difficult.

4. Apply a bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent to a thickness of 3-6 mm (1/8-1/4 in) to both of the mating surfaces.
5. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.
6. Apply a 9-13 mm (3/8-1/2 in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent to the service part mating surface.

Important: Do NOT pull the panels apart after joined together. Slide the panels against each other to realign the panels.

7. Install the body rear end panel to the vehicle.
8. Clamp the body rear end panel into position as required.
9. Using lacquer thinner remove the excess adhesive from the panel area.
10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
11. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
14. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.