Chevrolet Trax: Front compartment side rail sectioning

Removal Procedure

WARNING: Refer to Approved Equipment for Collision Repair Warning .

WARNING: Refer to Collision Sectioning Warning .

WARNING: Refer to Glass and Sheet Metal Handling Warning .

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 the related panels and components.
4. Visually inspect the damage. 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 (Base) .

Fig. 31: Front Compartment Side Rail

6. Locate the die mark on the inner lower surface of the front compartment side rail.

NOTE: Do not section the rail in any area other than the die mark location given.

7. Align a sliding square or similar tool to the line at the tip of the arrow in the die mark. Scribe a line across the rail.

Fig. 32: Sectioning Replacement Side Rail

NOTE: Do not damage any other panels or reinforcements.

8. Cut the panel where sectioning is to be performed (1).

Fig. 33: Front Compartment Side Rail

9. Remove the damaged front compartment side rail (1).
10. Drill two 8 mm (5/16 in) plug weld holes on each of the 3 sides of the front compartment side rail (1).

    Position the center of the holes 10 mm (3/8 in) from the cut edge.

Installation Procedure

1. Locate the original cutting line on the service part front compartment side rail.
2. Align a sliding square or similar tool to the original cutting line and scribe a line across the rail.
3. Use the same tool to transfer this scribed line onto the sides and the weld flanges of the rail.
4. Place a mark forward, 25 mm (1 in) from the scribed line on all 3 sides of the service rail.
5. Use the tool to scribe a line on all 3 sides and weld flanges of the rail.

Fig. 34: Scribe Marks On Rail

6. Cut at the scribe line (1).
7. Remove the front portion of the rail.

Fig. 35: Rear Side Rail Outer Flanges

8. Cut the upper outer flanges of the front portion of the front compartment side rail service part. Cut the flanges back to the first scribe line and remove the tabs.
9. Cut the lower radius corners of the service part back to the first scribe line and remove the small corners.
10.  Bend the bottom side of the service part at the sectioning location inward slightly by aligning a vice grip flanging tool or similar tool at the first scribed line.
11. Clean and prepare the attaching surfaces for welding

Fig. 36: Front Compartment Side Rail

12. Position the front compartment side rail (1) on the vehicle.

Fig. 37: Plug Welding Front Compartment Side Rail

13. Tack weld (1) the part into position.
14. Inspect the service front compartment side rail for proper dimensions, using 3-dimensional measuring equipment.
15. Plug weld at each 8 mm (5/16 in) plug weld hole location.
16. Stitch weld along the entire sectioning joint. Make welds along the seam with 25 mm (1 in) gaps between. Weld the gaps.
17. Clean and prepare the welded surfaces.
18. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) .
19. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
20. Install all related panels and components.
21.  Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
22. Enable the SIR system. Refer to SIR Disabling and Enabling .

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