Research Bulletin 1994-7

 

Outer Door Panel Bond Separation

Introduction

Vehicles Affected: 1993 - 1994 Chevrolet Camaro and Pontiac Firebird here have been several reports that the structural adhesive bond between the door frame and outer panel can separate following a collision on the General Motors Camaro and Firebird models. General Motors is aware of this problems and has issued a service GM bulletin #431028, that addresses this issue and describes their recommended repair procedures to the situation. Most reports indicate that the outer door panel separates from the door frame the lower hem flange seam, particularly after air bag deployment. The cause may be due to insufficient adhesive in the hem flange bonding area.

Repair facilities should follow the recommended repair procedures listed in the GM service bulletin. The GM service part #12345726 Structural Bonding Adhesive, Lord Fusor SMC Body Bonding Repair Adhesive, or Dominion/American Sure Seal #XRGM Adhesive and heart lamp(s) are required for the repair. If the GM structural bonding adhesive is not available, the Lord Fusor material can be ordered from 1-800-525- 7939.

Deployment of the air bag modules creates a very rapid air pressure increase in the passenger compartment. Release of this air pressure may possibly contribute to the separation of the adhesive bond in the hem flange, as air is rapidly forced out of the vehicle.

If the bond separation condition is noted, and the door outer panel and frame have not been directly impacted, contact a local General Motors dealer to advise them of the situation and obtain their approval before repairs are initiated. Repairing the door panel may be corrected under warranty.

The information provided in this bulletin is for educational purposes only. Although every effort has been made to ensure the accuracy of the information contained in this bulletin, Tech-Cor assumes no responsibility or liability for any repairs performed using information from any publication issued by Tech-Cor.

Any person performing repairs must determine whether any suggested or recommended procedures or repairs are suitable or appropriate for the particular vehicle being repaired. The repairer remains solely responsible for such determination, as well as for the proper completion of the repairs.

Reproduction of this bulletin is not permitted without the written approval of Tech-Cor.

Tech-Cor, LLC, Wheeling, IL
© 1994 Allstate Insurance Company
All rights reserved.

GM Service Bulletin: 431028 May, 1994

LOOSE DOOR OUTER PANELS, BOND SEPARATIONS AT HEM AREA (REPAIR GUIDELINES AND PROCEDURES)

Models: 1993-94 Chevrolet Camaro; 1993-94 Pontiac Firebird

This bulletin is being issued to provide information regarding various door outer panel separations and some guidelines to select the proper repair procedures.

It is expected that these repairs will be made in a quality body repair facility by an experienced body technician using the proper equipment and materials.

CONDITION

Some outer door panels may have a bond separation at the hem area. These separations may be seen as:

TYPE 1

Bond separation at the rear hem, from the outer belt strip to the body side molding.

TYPE 2

Bond separation for the full length of the rear hem and part of the lower edge along the rocker (but no surface damage to inner or outer panel).

TYPE 3

Bond separation as in type 2, but either:

  1. The outer panel has some surface cracking (usually near the outer handle), OR,
  2. The inner panel has some surface cracking in the hem bonding area.

CAUSE

May be due to insufficient adhesive in the hem bonding area.

CORRECTION

TYPE 1

Rebond the door outer panel to the inner hem area using the appropriate procedure.

TYPE 2

Reinstall the original door outer panel to the original inner panel using the appropriate procedure.

TYPE 3

  1. Replace the door outer panel using the appropriate procedure.
  2. Replace the door assembly.

MATERIALS REQ'D: GM #12345726 Structural Bonding Adhesive OR Lord Fusor SMC Body Panel Repair Adhesive OR Dominion/American Sure Seal # XRGM Adhesive, and portable heat lamp(s).

NOTE: If the GM Structural Bonding Adhesive is not available, the Lord Fusor material can be ordered from 1-800-525-7939.

We believe these sources and their product to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources.

PROCEDURE FOR TYPE 1 REPAIR: (Partial separation of panels).

  1. Lower door glass.

    NOTE: Prior to disconnecting the battery cable, the radio station settings should be reviewed, recorded and then reset for the customer prior to delivery.

  2. Disconnect negative battery cable.

  3. Use a "block" to hold the inner and outer panels slightly apart at the rear belt opening.

  4. Carefully clean any dirt residue that may be present in the bonding area with Isopropyl Alcohol and a clean lint free rag.

  5. Prepare 3 to 4 clamps to correct dimension for clamping outer panel to inner panel, including space for protective material for the door outer panel surface.

    NOTE: Be sure that the clamp pressure allows a slight gap for adhesive thickness (approximately .75 mm or .030") and is not so high that the panel surfaces are distorted, or panel refinish repairs will be necessary.

  6. Apply a sufficient bead of GM #12345726 Structural Bonding Adhesive or equivalent to the hem bonding area.

  7. Press the outer panel to the inner panel and check the adhesive "wet out" pattern to ensure the entire hem flange has adhesive present. If necessary, add more adhesive.

  8. While holding the panels together, clean any adhesive squeeze out in the hem area prior to adhesive curing.

  9. Clamp the panels together at the predetermined locations.

  10. Apply the manufacturer's recommended curing processes and time requirements (typically require some type of heat cure cycle).

  11. After the heat cure cycle, remove the lamp and allow vehicle surfaces to return to room temperature.

  12. Apply touch up paint to any exposed adhesive squeeze out

    Labor Operation: A9340 Right Side A9341 Left Side
    Labor Time: Use Published Labor Operation Time.
    Material Allowance: $15.00 for adhesive materials.

PROCEDURE FOR TYPE 2 REPAIR: (Reinstall the original outer panel to the original inner panel).

  1. Lower the door glass.

    NOTE: Prior to disconnecting the battery cable, the radio station settings should be reviewed, recorded and then reset for the customer prior to delivery.

  2. Disconnect negative battery cable.

  3. Remove the door trim panel, water deflector and disconnect the rods to the outside handle and lock cylinder.

  4. Disconnect and remove the door wiring harness.

  5. Remove the door assembly from the vehicle and place on a stand, inner panel side down.

  6. Using a heat gun and a pry tool, apply heat to the bond area from the inner panel side and carefully pry the panels apart as the heat softens the adhesive.

  7. Once the panels are apart, clean any loose or excess adhesive from the bonding areas on both panels with a sharpened putty knife or scraper.

  8. Rough up the bond areas on both panels with a piece of #80 grit sandpaper to promote adhesion, and blow off the sanding dust with an air hose.

  9. Prepare a number of clamps (approximately 15 to 20) for holding the outer panel to the inner panel during adhesive cure.

    NOTE: Be sure to allow enough room for protective pads on the outer panel and adhesive gap (approximately .75 mm or .030").

  10. Apply a 6 mm (1/4") to 8 mm (5/16") bead of adhesive material to the inner panel hem flange bond area.

  11. With the aid of a helper, position the outer panel to the inner panel, and clamp the two panels together.

  12. Apply the manufacturer's recommended curing process and time requirements (typically require some type of heat cure cycle).

  13. After the heat cure cycle, remove the heat source and allow the door to return to room temperature.

  14. Apply touch up paint to any exposed adhesive squeeze out.

  15. Reinstall and properly align the door assembly to the vehicle.

    NOTE: Prior to delivery to the customer, the vehicle should be road tested for wind noise and water leaks to ensure proper door alignment.

  16. Reinstall the wiring harness, lock cylinder and outside handle rods, water deflector and trim panel.

  17. Reconnect the battery cable and reset radio stations.

    Labor Operation: S0800 (Right) S0801 (Left)
    Labor Time: Use Published Labor Operation Time.
    Material Allowance: $35.00 for adhesive materials.

PROCEDURE FOR TYPE 3 REPAIR: (If damage is present in the outer panel surface, install new outer panel).

Follow the same procedure for Type 2 repairs except that a new door outer panel is installed (and requires painting), and the body side molding must be transferred or replaced. Once the new outer panel is installed, the new door assembly should be "cut in" with body color and clearcoated prior to installation to the body.

Labor Operation: S0800 (Right),
PLUS: A1230 (Refinish, Right)
OR
S0801 (Left),
PLUS: A1231 (Refinish, Left)
Labor Time: Use Published Labor Operation Time.
Material Allowance:GL (for paint materials).
$35.00 for adhesive materials.

DOOR ASSEMBLY REPLACEMENT (If inner panel flange is damaged).

The complete door assembly should be replaced, with the inside surfaces and edges of the door "cut in" with body color and clearcoated prior to installation to the body.

Once the hardware is transferred from the original door to the new door, the door and glass assemblies should be aligned properly, and (after painting the door assembly) should be road tested and water tested for wind noise or water leaks.

NOTE: The procedures to obtain new decals or the decal information on the rear facing of the door should be followed.

Labor Operation: S0850 (Right),
PLUS: A1230 (Refinish, Right)
S0851 (Left),
PLUS: A1231 (Refinish, Left)
Labor Time: Use Published Labor Operation Time.
Material Allowance: GL (for paint materials).

PART AVAILABILITY:

Parts are currently available from GMSPO.

Copyright 1994
General Motors Corporation.
All Rights Reserved.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer." They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist In the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a lob properly and safety, If a condition la described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM Dealer for information on whether your vehicle may benefit from the information.