Rear Bumper Impact Bar Replacement (Z06, ZR1)

Rear Bumper Impact Bar Replacement (Z06)

Tools Required

J 42058 Frame Adapter Clamp

CAUTION: Refer to Approved Equipment for Collision Repair Caution.

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. Repair as much of the damage as possible to the factory specifications.
5. Use J42058 to secure the vehicle if pulling and straightening are required.
6. Note the location and remove the sealers and anti-corrosion materials from the repair area. Refer to Anti-Corrosion Treatment and Repair.






IMPORTANT:
- Hand tools, saw blades and abrasives used for aluminum repairs should be dedicated for aluminum only to prevent contamination.
- When removing welds, favor the bumper bar side of the weld joint.

7. Locate and remove all factory welds (1) attaching the rear bumper bar to the bottom of the rear frame rails. Note the location of the welds for installation of the new bumper bar.






1. Locate and remove all factory welds (1) attaching the rear bumper bar to the outer and inner of the rear frame rails. Note the location of the welds for installation of the new bumper bar.






1. Locate and remove all factory welds (1) attaching the rear bumper bar to the battery tray. Note the location of the welds for installation of the new bumper bar.






1. Locate and remove all factory welds (1) attaching the rear bumper bar to the top of the rear frame rails. Note the location of the welds for installation of the new bumper bar.






1. Using a heat gun, detach the adhesive from the rear bar (1) to the rear compartment panel.
2. Remove the damaged bumper bar.






1. Locate and remove all factory welds (1) attaching the battery tray to the battery tray bracket. Note the location of the welds for installation of the battery tray.






1. Using a heat gun, detach the adhesive from the battery tray to the rear compartment panel.
2. Remove the battery tray (1).






1. Remove pieces of the bumper bar which are left attached to the rail ends.
2. Straighten and deburr the rail ends. Keep the perimeter and shape of the rail end as original as possible.

Installation Procedure






IMPORTANT: Due to welding accessibility, it may be necessary to weld the triangle brackets (1) to the bumper bar prior to installation of the bumper bar.

1. Dry fit the bumper bar for proper fit and alignment before welding.

IMPORTANT: Use a stainless steel brush to remove the oxide layer prior to welding.

2. Clean and prepare all of the welded mating surfaces.
3. Install the rear bumper bar.
4. Position the bumper bar to the vehicle using 3-dimensional measuring equipment.






IMPORTANT: Recommended wire alloy is 5356 and wire size is.035. The shielding gas is 100 percent Argon. A 2 minute cooling down period is recommended for every 2 minutes or 100 mm (4 in) of welding.

1. Using a P-MIG welder, weld (1) the bumper bar to the top of the rear frame rails duplicating the factory welds.






1. Using a P-MIG welder, weld (1) the bumper bar to the bottom of the rear frame rails duplicating the factory welds.






1. Using a P-MIG welder, weld (1) the bumper bar to the outer and inner of the rear frame rails duplicating the factory welds.






IMPORTANT: DO NOT top coat the bonding surface of the battery tray. Use primer only on bonding surfaces. Refer to adhesive manufacturer's recommendations.

1. Clean and prepare all bonding mating surfaces according to adhesive manufacturer's recommendations.
2. Apply a consistent bead of structural adhesive to the battery tray to bond to the rear compartment panel. Refer to Sheet Molded Compound (SMC) Panel Bonding.
3. install the battery tray (1).
4. Clamp or mechanically fasten the battery tray into place as necessary.






IMPORTANT: Due to welding accessibility, it may be necessary to change the weld location of the battery tray to the rear bumper bar.

1. Using a P-MIG welder, weld (1) the battery tray to the bottom of the bumper bar.






1. Using a P-MIG welder, weld (1) the outer edge of the battery tray to the bumper bar.






1. Using a P-MIG welder, weld (1) the battery tray to the battery tray bracket.






IMPORTANT: DO NOT top coat the bonding surface of the rear bar. Use primer only on bonding surfaces. Refer to adhesive manufacturer's recommendations.

1. Clean and prepare all bonding mating surfaces according to adhesive manufacturer's recommendations.
2. Apply a consistent bead of structural adhesive to the top impact bar to bond to the rear compartment panel. Refer to Sheet Molded Compound (SMC) Panel Bonding.
3. Apply the sealers and anti-corrosion materials to the repair area. Refer to Anti-Corrosion Treatment and Repair.
4. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
5. Install all related panels and components.
6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
7. Enable the SIR system. Refer to SIR Disabling and Enabling.