Chevrolet Trax: Front side door outer panel replacement

Special Tools

• BO-6392 Flanging Tool Kit
• BO-6396 Bonding Pliers

For equivalent regional tools, refer to Special Tools.

NOTE: According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Removal Procedure

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 the front side door. Refer to Front Side Door Replacement .
4. Remove the front side door outside handle. Refer to Front Side Door Outside Handle Replacement .
5. Remove the outside rearview mirror. Refer to Outside Rearview Mirror Replacement .
6. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair (Base) .

Fig. 85: Grinding Edge Of Side Door Outer Panel

7. Grind the edges of the front side door outer panel (1) to separate the outer door panel from the door shell.

Fig. 86: Front Side Door Outer Door Panel

8. Remove the front side door outer door panel (1).
9.  Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti- Corrosion Treatment and Repair (Base) .
10. Straighten the edges of the door shell.

Installation Procedure

1. Align the front side door outer panel.
2. Verify the fit of the front side door outer panel.

Fig. 87: Front Side Door Outer Door Panel

3. Clamp the front side door outer panel (1) into position.
4. Pre-flanging the flange with BO-6396 pliers and BO-6392 tool kit.

Fig. 88: Front Side Door Outer Door Panel Hem Flanges

5. Continue to hammer in stages along the hem flanges (1).
6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) .
7. Install the outside rearview mirror. Refer to Outside Rearview Mirror Replacement .
8. Install the front side door outside handle. Refer to Front Side Door Outside Handle Replacement .
9. Install the front side door. Refer to Front Side Door Replacement .
10. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
11. Install all related panels and components.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
13. Enable the SIR system. Refer to SIR Disabling and Enabling .

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