11.

REAR RAIL
The left and right rear rails are available as complete sub-assemblies and can be replaced in their entirety similar to past model procedures. However, sectioning can be used to simplify repairs if damage is limited to the rear 600mm (24") of the rail. Templates and instruction sheets are packaged with the parts to facilitate service. When replacing a rail in its entirety, the weld flange that mates with the wheelhouse must be bent upwards. The service assembly is supplied with this flange in a horizontal position (Figure 11-1). It is recommended that the service part be prepared before removing the damaged section of the rail from the vehicle. This will help you become familiar with the procedure and know exactly where to cut the damaged rail for a better fit of the new section. It will also help you locate the rear rail inner reinforcement.

REAR RAIL SECTIONING PROCEDURE

Prepare the Service Part
1. Invert the service part and secure it to a bench for cutting. 2. Align the appropriate template on the underside of the rail. Use a center punch or an awl to mark the rail by punching through the template. Remove the template and connect the dots with a straight edge and scribe the cut line. Notice The cut lines for the left and right sides are in different positions. Make sure to use the appropriate template. Do not damage the template since it must also be used to mark the original rail. Attach it with a non-permanent spray adhesive such as 3Ms Repositionable Adhesive (part #6091). 3. Cut through the outer panel and inner reinforcement along the line and remove the excess portion of the service part. 4. Drill out the welds attaching the inner reinforcement to the outer panel (typically three welds). Remove the inner reinforcement.

Service assembly supplied with horizontal wheelhouse flange

Service assembly with wheelhouse flange bent upwards for installation

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1995 General Motors Corporation. All Rights Reserved.

FIGURE 11-1 REAR RAIL ASSEMBLY

CAVALIER/SUNFIRE COLLISION REPAIR ISSUES

11. REAR RAIL

Remove or Disconnect
1. Remove all related panels and components including the fuel tank, fuel filler neck and exhaust system. 2. Visually inspect and restore as much of the damage as possible to factory specifications. 3. Remove sealers, sound deadeners and corrosion materials as necessary. 4. Align the appropriate template on the underside of the rail. Use a center punch or an awl to mark the rail by punching through the template. Remove the template and connect the dots with a straight edge and scribe the cut line. 5. Locate, mark and drill out the factory welds rearward of the marked cut line, including those securing the rear rail inner reinforcement to the outer panel. Do not drill through the inner reinforcement (Figure 11-2). 6. Cut the rail along the rough cut line. Remove the damaged section of the rear rail. 7. Separate the side walls of the inner reinforcement from the outer panel of the rail by slightly prying the reinforcement inwards. 8. Cut the sides of the rail outer panel along the final cut line, taking care not to damage the inner reinforcement. Cut along the bottom of the outer panel approximately 3/4 of the metal thickness deep. Notice Be careful not to cut the inner reinforcement. This reinforcement will act as a backing plate when welding the new rail section in place. 9. Bend the rail down and up until the outer panel breaks along the partial cut. Remove the damaged section of the rear rail, leaving the reinforcement extending from inside the remaining rail section (Figure 11-3)

"Final" cut line

F IGURE 11-2 CUT AND REMOVE THE DAMAGED SECTION OF THE REAR RAIL

FIGURE 11-3 LEAVE INNER REINFORCEMENT EXTENDING FROM ORIGINAL RAIL

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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.

11. REAR RAIL

Install or Connect
1. Prepare mating surfaces and position the service part, allowing it to slide over the inner reinforcement extending from the original rail section. Check fit using body dimensions and plug weld accordingly with frequent measurements to ensure proper fit. Notice Make sure to plug weld the inner reinforcement to the new rail section. This may require drawing the reinforcement flat against the rail using a screw. It may be necessary to install backing plates on either side of the original rail above the inner reinforcement. These can be cut from the unused inner reinforcement of the service part. Drill holes and plug weld the backing plates in place (Figure 11-4). 5. Stitch weld along the entire joint. Make 25mm (1") welds along the seam with 25mm (1") gaps between. Then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion. Notice To ensure a secure weld, the sectioning joints should have a gap of approximately one-and-a-half times the thickness of the metal. Trim the parts as necessary to achieve this. 6. Clean and prepare welded surfaces. Prime with two-part catalyzed primer. Apply sealers and corrosion protection materials, as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Reinstall all related panels and components.

FIGURE 11-4 INSTALL BACKING PLATES AND WELD NEW SECTION

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CAVALIER/SUNFIRE COLLISION REPAIR ISSUES
1995 General Motors Corporation. All Rights Reserved.