GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Grand Am 🢒 Body 🢒 Collision Repair 🢒 General Door Frame Opening Sectioning

Removal Procedure

    Object Number: 404404 Size: SH

    Important: When sectioning areas other than the hinge pillar, a 100 mm (4 in) backing plate must be used behind the joint to ensure a solid and secure weld in areas where there is no inner reinforcement. Backing plates can usually be cut from the unused portion of the service part or an undamaghed section of the door frame opening. There are some key reinforcements that are to be replaced at factory seams only. Sectioning these panels may compromise the structural integrity of the vehicle. The rocker panel can also be replaced in its entirety when the quarter panel has been removed.

  1. Remove all related panels and components.
  2. Visually inspect and restore as much of the damage as possible to factory specifications.
  3. Remove the following as necessary:
    4. • Sealers
    • Sound deadeners
    • Anti-corrosion materials
  4. Cut the door frame opening where it is to be sectioned. Do not damage any inner panels or reinforcements.
  5. Locate, mark and drill out all necessary factory welds. Note the number of welds for installation of the service part.
  6. Remove the damaged section of the door frame opening.

Installation Procedure

    Object Number: 404407 Size: MH
  1. Cut the service part to match the undamaged section of the door frame opening.
  2. Remove the unused portion of the service part.
  3. Cut a 100 mm (4 in) backing plate from the unused portion of the service part or undamaged section of the door frame opening. Modify the backing plate as necessary so that it will fit behind the sectioning joint (1).
  4. Sectioning the rocker panel requires a 100 mm (4 in) backing plate for reinforcement. Section within the recommended area.
  5. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original section of the service part.
  6. Drill plug weld holes along the sectioning cut on both the service part and the remaining original part.
  7. Prepare mating surfaces and slide the backing plates half way under the sectioning cuts on the vehicle.
  8. Plug weld in place.
  9. Position the service part, allow it to overlap the exposed portion of the backing plates.
  10. Use body dimensions to check fit.
  11. Plug weld accordingly with frequent measurements to ensure proper fit.
  12. Stitch weld along the sectioning joints.
  13. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
  14. Complete the stitch weld.
  15. Complete all other welds as necessary.
  16. Clean and prepare welded surfaces.

    17. Important: Prior to refinishing, refer to the publication GM 4901M-2000 "GM Approved Refinish Materials" for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

  17. Apply approved anti-corrosion primer.
  18. Apply sealers and refinish as necessary.
  19. Install all related panels and components.