Chevrolet Sonic Repair Manual: Full-Cut Method Description
Note:
- If corrosion of the pinch-weld flange is present, or if sheet metal repairs or replacements are required, refinish the pinch-weld flange in order to present a clean, primer-only surface.
- If paint repairs are required, mask the flange bonding area, prior to applying the color coat, in order to provide a clean, primer-only surface.
- Appropriate materials for these primer applications are typically 2 component catalyzed products. Use materials such as BASF?€‰DE15?®, DuPont?€‰2610?®, Sherwin-Williams PSE?€‰4600 and NP70?® and Martin-Semour?€‰5120 ,5130?® , PPG?€‰DP90LF SPIES/HECKER?€‰3688/8590 ?€“ 3688/5150 ?€“ 4070/5090 STANDOX?€‰11158/13320 ?€“ 14653/14980 products are approved for this application. Follow the manufacturer's directions for the mix, the application, and the drying times.
- After repairing the opening as indicated, shake the pinch-weld primer black?€‰#3 well. Using a new dauber, apply the primer to the primed surface of the flange in the bonding area. Allow the primer to dry for 10?€‰minutes.
Use only the full cut method, also known in the field as full strip method, when installing windows.
This method includes the following:
- The replacement of a majority of the urethane adhesive bead. Remove all but approximately 2 mm?€‰(3/64?€‰in) of the existing bead of urethane adhesive from the pinch-weld flange.
- Apply pinch-weld primer to any exposed painted areas on the pinch-weld flange.
No mounds or loose pieces of urethane adhesive should remain on the pinch-weld flange. Do not remove all traces of urethane adhesive.
Front Side Door Window Weatherstrip Replacement
Front Side Door Window Weatherstrip Replacement
Callout
Component Name
Preliminary Procedures
Remove front side door trim panel. Re ...
Liftgate Window Replacement
Special Tools
BO-24402-A Glass Sealant Remover (Cold Knife)
BO-39032 Stationary Glass Removal Tool
Use an adhesive that is approved by GM
For equivalent regional tools, refer to Special Too ...
Other materials:
Protecting Exterior Bright Metal Moldings
Caution
Failure to clean and protect the bright metal moldings can result in a hazy
white finish or pitting. This damage would not be covered by the vehicle warranty.
The bright metal moldings on the vehicle are aluminum. To prevent damage always
follow these cleaning instructions:
Be sure ...
Instrument Panel Upper Trim Panel Replacement - Right Side
Instrument Panel Upper Trim Panel Replacement - Right Side
Callout
Component Name
Preliminary Procedure
Disable the SIR system. Refer to SIR Disabling and Enabling.
Remove the instrument panel center molding. Refer to Inst ...
Main Shaft Disassemble (Gen 2)
Special Tools
69604356 Gear Pullers
For equivalent regional tools, refer to Special Tools.
Remove the 1st gear thrust washer (1) and the 1st gear (2)
using 69604356 pullersand a hydraulic press.
ii
Remove the following components:
1st gear bearing asse ...
0.0065