Service Procedure

1. Disconnect negative (-) battery cable.

2. Remove rear tire/wheel assemblies.

3. Remove rear wheelhouse inner panels.

4. Remove rear facia. Refer to Corvette Service Manual, Section 2B-4.

5. Disconnect power antenna at rear upper panel. (Left side panel replacement only).

ILLUSTRATION 1 - REAR UPPER PANEL:

6. Using cut-off wheel or die grinder cut a section of the rear roof panel away to gain access. (See Illustration 1).

7. Remove rear roof section by applying heat from heat gun and prying loose. Save this section for reinstallation.

ILLUSTRATION 2 - LOCK PILLAR ACCESS HOLE AND INSULATOR:

8. Remove screws from sill plate at lock pillar and loosen load floor carpet to gain access to lock pillar access hole and insulator. (See Illustration 2).

9. Remove insulator, P/N 14065008, and any other flammable material from the inside of the lock pillar.

10. Open rear hatch and remove weatherstrip trim molding and weatherstrip from area of panel(s) to be replaced.

ILLUSTRATION 3 - BOND LOCATIONS:

11. For either side replacement, remove complete outer skin by using heat gun and pressure, lifting skin away from inner structure. (See Illustration 3 for bond locations).

12. Remove all remaining adhesive by using heat gun and putty knife.

ILLUSTRATION 4 - UPPER REAR QUARTER PANEL:

13. Fit and check alignment of new upper rear quarter panel, then drill two 1/8" diameter guide holes for sheet metal screws. (See Illustration 4). Remove screws and panel.

ILLUSTRATION 5BRACE (RIGHT SIDE SHOWN):

14. Remove underbody braces and discard (See Illustration 5).

ILLUSTRATION 6PLATE (RIGHT SIDE SHOWN):

15. Remove underbody plates and discard (See Illustration 6).

ILLUSTRATION 7 - UNDERSIDE OF THE REAR FLOOR:

16. Remove all excess bonding agent from the underside of the rear floor so that the brackets, P/N 14091061-2, fit flush on the underbody. (See Illustration 7).

17. Hand fit the bracket into position. (Using grinder and hammer). Make sure that the bracket lays flush against both the frame and underbody.

ILLUSTRATION 7 - UNDERSIDE OF THE REAR FLOOR:

ILLUSTRATION 8 - BRACKET LOCATION:

18. With bracket hand held in place drill two rivet holes. (See Illustration 8) (use 1/8 diameter long shank rivet).

19. Clean and sand the bonding surfaces of the underbody and brackets.

20. Grind the area on the frame and bracket where the bracket will be welded on.

21. Apply epoxy adhesive (Fusor 320/322) to the top of the bracket. Use recommended epoxy.

22. Locate the two pop rivets (Reg. TM) and install.

ILLUSTRATION 9 - BRACKET WELDING LOCATION:

23. MIG weld (ER70s-6 wire) the bracket to the frame at indicated locations, one weld at a time, allowing each weld to cool. (See Illustration 9).

24. Clean, prime and paint the brackets.

25. Scuff the area on the new panels to be bonded. Then clean with wax and grease remover solvent.

26. Mix epoxy until uniform color with no streaks (use 1/2 pint of Fusor 320 part A and 1/2 pint of Fusor 322 part B per side). See attachment for ordering epoxy.

27. Use plastic bag for application of epoxy. (Large zip-lock (Reg. TM) bag is preferred). Put epoxy into bag and cut corner off to get a 3/8" diameter bead.

ILLUSTRATION 10:

28. Apply bead to bond surfaces on vehicle.

29. Install upper quarter panel and fit. Insert alignment screws and clamp loosely where necessary to fit. Be sure front top corner of rear upper quarter panel is held below inner surface of outer roof panel. (See Illustration 10).

30. Let set for thirty (30) minutes.

31. Remove clamps and screws.

ILLUSTRATION 11:

32. Use epoxy adhesive (Fusor 320/322) to set in the roof panel section removed earlier. (See Illustration 11).

33. V-groove and apply polyester filler.

34. Sand.

35. Prime and paint.

ILLUSTRATION 12:

36. Mark and drill rear fascia holes (See Illustration 12).

37. Reverse tear down procedure.
LABOR OPERATION LABOR
NUMBER TIME
Inc. refinish and paint as necessary.

Install L.H. Panel, both T1178 10.8 GI
brackets
Add to clear coat .3 CD

Install R.H. Panel, both T1179 11.0 GI
brackets
Add to clear coat .3 CD

Install panels on both sides, T1180 14.9 GI
both brackets
Add to clear coat .6 CD