Body Tail Lamp Filler Panel Replacement With Extension Panel SWB

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

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the rear interior trims. Refer to Quarter Upper Trim Panel Replacement.
4. Remove the rear compartment side trims. Refer to Rear Corner Trim Panel Carpet Replacement.
5. Remove the battery. Refer to Battery Replacement.
6. Remove the battery tray. Refer to Battery Tray Replacement.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
8. Remove the rear wheels. Refer to Tire and Wheel Removal and Installation.
9. Remove the rear impact bar. Refer to Rear Bumper Fascia Insert Replacement.
10. Remove the rear pressure relief valves. Refer to Pressure Relief Valve Replacement.
11. Remove the tail lights. Refer to Parking and Turn Signal Lamp Replacement.



12. Locate, mark and drill out the spot welds (1) in the tail lamp filler and rear extension panel to rear quarter panel.
13. Locate, mark and drill out the spot welds (3) in the rear extension panel to side extension panel.
14. Locate, mark and drill out the spot welds in the tail lamp filler panel to side extension panel.
15. Locate, mark and drill out the spot welds (2) in the tail lamp filler panel to rear end panel.



16. Locate, mark and drill out the spot welds (1) in the tail lamp filler panel to inner upper extension panel.
17. Remove the tail lamp filler panel and extension panel from the vehicle.

Important: If the location of the original spot weld holes can not be determined, or if structural weld-thru adhesive is present, space the puddle weld holes every 32 mm (1¼ in).

Important: Spot welding is the preferred method for attaching panels and should be used wherever possible. A puddle weld should be performed where your spot welder is unable to reach.




1. Apply the primary sealer (1) GM6449G or equivalent along the tail lamp filler panel and rear extension panel to the rear quarter panel.
2. Position the tail lamp filler panel to the vehicle.



3. Align the datum hole alignment points at A, B and C.

•	Datum A is 10.5mm

•	Datum B is 10.2mm X 16.1mm

•	Datum C is 23.1mm




4. Weld (1) the tail light filler panel to the inner upper extension panel.



5. Weld the tail lamp filler panel to the rear end panel.
6. Weld the tail lamp filler panel to the side extension.
7. Weld the rear extension panel to the side extension panel.
8. Weld the tail lamp filler panel and the rear extension panel to the rear quarter panel.



9. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel and side extension to the rear quarter panel.



10. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel to the rear end panel.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
12. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
13. Install the tail lights. Refer to Parking and Turn Signal Lamp Replacement.
14. Install the pressure relief valves. Refer to Pressure Relief Valve Replacement .
15. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
16. Install the rear wheels. Refer to Tire and Wheel Removal and Installation.
17. Install the battery tray. Refer to Battery Tray Replacement.
18. Install the battery. Refer to Battery Replacement.
19. Install the rear compartment side trims. Refer to Rear Corner Trim Panel Carpet Replacement.
20. Install the rear interior trims. Refer to Quarter Upper Trim Panel Replacement.

Caution: Refer to Battery Disconnect Caution in the Preface section.

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.
23. If re-programming is required. Refer to Control Module References.

Body Tail Lamp Filler Panel Replacement SWB

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

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the rear compartment side trims. Refer to Rear Corner Trim Panel Carpet Replacement.
4. Remove the rear interior trims. Refer to Quarter Upper Trim Panel Replacement.
5. Remove the battery. Refer to Battery Replacement.
6. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
7. Remove the tail lights. Refer to Parking and Turn Signal Lamp Replacement.



8. Locate, mark and drill out the spot welds in the tail lamp filler panel to rear quarter panel.
9. Locate, mark and drill out the spot welds in the tail lamp filler panel to rear end panel.
10. Locate, mark and drill out the spot welds in the tail lamp filler panel to side extension.



11. Locate, mark and drill out the spot welds in the tail lamp filler panel to upper extension.
12. Remove the tail lamp filler panel from the vehicle.

1. Apply the primary sealer (1) GM6449G or equivalent path to the tail lamp filler panel.
2. Install the tail lamp filler panel to the vehicle.



3. Align the datum hole alignment points at A, B and C.

•	Datum A is 4.1mm

•	Datum B is 10.2mm X 16.1mm

•	Datum C is 10.5mm




4. Weld (1) the tail light filler panel to the upper extension.



5. Weld (1) the tail light filler panel to the side extension.



6. Weld (1) the tail lamp filler panel to the rear end panel.



7. Weld (1) the tail lamp filler panel to the rear quarter panel.



8. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel to the rear quarter panel.
9. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel to the rear end panel.
10. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel to the side extension panel.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
12. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
13. Install the tail lights. Refer to Parking and Turn Signal Lamp Replacement.
14. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
15. Install the battery. Refer to Battery Replacement.
16. Install the rear compartment side trims. Refer to Rear Corner Trim Panel Carpet Replacement.
17. Install the rear interior trims. Refer to Quarter Upper Trim Panel Replacement.

Caution: Refer to Battery Disconnect Caution in the Preface section.

18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
19. Enable the SIR system. Refer to SIR Disabling and Enabling.
20. If re-programming is required. Refer to Control Module References.

Body Tail Lamp Filler Panel Replacement With Extension Panel LWB

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

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the rear interior trims. Refer to Quarter Upper Trim Panel Replacement.
4. Remove the rear compartment side trims. Refer to Rear Corner Trim Panel Carpet Replacement.
5. Remove the battery. Refer to Battery Replacement.
6. Remove the battery tray. Refer to Battery Tray Replacement.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
8. Remove the rear wheels. Refer to Tire and Wheel Removal and Installation.
9. Remove the rear impact bar. Refer to Rear Bumper Fascia Insert Replacement.
10. Remove the rear pressure relief valves. Refer to Pressure Relief Valve Replacement.
11. Remove the tail lights. Refer to Parking and Turn Signal Lamp Replacement.



12. Locate, mark and drill out the spot welds in the tail lamp filler and rear extension panel to rear quarter panel.
13. Locate, mark and drill out the spot welds in the rear extension panel to side extension panel.
14. Locate, mark and drill out the spot welds in the tail lamp filler panel to side extension panel.
15. Locate, mark and drill out the spot welds in the tail lamp filler panel to rear end panel.



16. Locate, mark and drill out the spot welds (1) in the tail lamp filler panel to inner upper extension panel.
17. Remove the tail lamp filler panel and extension panel from the vehicle.

Important: If the location of the original spot weld holes can not be determined, or if structural weld-thru adhesive is present, space the puddle weld holes every 32 mm (1¼ in).

Important: Spot welding is the preferred method for attaching panels and should be used wherever possible. A puddle weld should be performed where your spot welder is unable to reach.




1. Apply the primary sealer (1) GM6449G or equivalent along the tail lamp filler panel and rear extension panel to the rear quarter panel.
2. Position the tail lamp filler panel to the vehicle.



3. Align the datum hole alignment points at A, B and C.

•	Datum A is 10.5mm

•	Datum B is 10.2mm X 16.1mm

•	Datum C is 23.1mm




4. Weld (1) the tail light filler panel to the inner upper extension panel.



5. Weld (1) the tail lamp filler panel to the rear end panel.



6. Weld (1) the tail lamp filler panel to the side extension.



7. Weld (1) the rear extension panel to the side extension panel.



8. Weld (1) the tail lamp filler panel and the rear extension panel to the rear quarter panel.



9. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel and side extension to the rear quarter panel.



10. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel to the rear end panel.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
12. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
13. Install the tail lights. Refer to Parking and Turn Signal Lamp Replacement
14. Install the pressure relief valves. Refer to Pressure Relief Valve Replacement.
15. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
16. Install the rear wheels. Refer to Tire and Wheel Removal and Installation.
17. Install the battery tray. Refer to Battery Tray Replacement.
18. Install the battery. Refer to Battery Replacement.
19. Install the rear compartment side trims. Refer to Rear Corner Trim Panel Carpet Replacement.
20. Install the rear interior trims. Refer to Quarter Upper Trim Panel Replacement.

Caution: Refer to Battery Disconnect Caution in the Preface section.

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.

Body Tail Lamp Filler Panel Replacement LWB

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

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the rear compartment side trims. Refer to Rear Compartment Side Trim Panel Replacement.
4. Remove the rear interior trims. Refer to Quarter Upper Trim Panel Replacement.
5. Remove the battery. Refer to Battery Replacement.
6. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
7. Remove the tail lights. Refer to Parking and Turn Signal Lamp Replacement.



8. Locate, mark and drill out the spot welds in the tail lamp filler panel to rear quarter panel.
9. Locate, mark and drill out the spot welds in the tail lamp filler panel to rear end panel.
10. Locate, mark and drill out the spot welds in the tail lamp filler panel to side extension.



11. Locate, mark and drill out the spot welds in the tail lamp filler panel to upper extension.
12. Remove the tail lamp filler panel from the vehicle.

1. Apply the primary sealer (1) GM6449G or equivalent path to the tail lamp filler panel.
2. Install the tail lamp filler panel to the vehicle.



3. Align the datum hole alignment points at A, B and C.

•	Datum A is 4.1mm

•	Datum B is 10.2mm X 16.1mm

•	Datum C is 10.5mm




4. Weld (1) the tail light filler panel to the upper extension.



5. Weld the tail light filler panel to the side extension.
6. Weld the tail lamp filler panel to the rear end panel.
7. Weld the tail lamp filler panel to the rear quarter panel.



8. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel to the rear quarter panel.
9. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel to the rear end panel.
10. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the tail lamp filler panel to the side extension panel.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
12. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
13. Install the tail lights. Refer to Parking and Turn Signal Lamp Replacement
14. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
15. Install the battery. Refer to Battery Replacement.
16. Install the rear compartment side trims. Refer to Rear Compartment Side Trim Panel Replacement.
17. Install the rear interior trims. Refer to Quarter Upper Trim Panel Replacement.

Caution: Refer to Battery Disconnect Caution in the Preface section.

18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
19. Enable the SIR system. Refer to SIR Disabling and Enabling.