Rail Replacement

The following procedure is applicable for either left side (96S48), if necessary, rail replacement.

This illustration shows a cutaway view of the left side rail and motor assembly. Right side rail and motor assembly symmetrically opposite.





Removal

1. Detach the shoulder belt from the buckle carrier.

2. Cycle the buckle carrier to the B-pillar (retracted position).

3. Install a memory saver, then disconnect the battery negative cable.

4. Remove the A to B-pillar trim panel. Refer to appropriate Service Manual.

5. Remove the quarter trim panel. Refer to appropriate Service Manual.





6. Disconnect the front limit electrical connector. See Figure 2.





7. Remove the three (3) rail upper mounting bolts. See Figure 3.





8. Remove the rail upper mounting screw. See Figure 4.





9. Remove the two (2) rail side mounting bolts. Refer to Figure 5.

10. Remove the two (2) cable retaining capscrews. See Figure 5.





11. Remove the three (3) motor mounting bolts. See Figure 6.

12. Disconnect the motor electrical connector.





13. Remove the rail and motor assembly from the vehicle. See Figure 7.





14. Place rail and motor assembly on bench with outboard side facing up. The red release button on the buckle carrier should be facing upward. Refer to Figure 8.

15. Remove roll pin. See Figure 8.





16. Using a small flat-bladed screwdriver, lift locking tab. See Figure 9.

17. Separate rail from locking tab.

NOTE:
Place cable assembly on clean workbench to prevent contamination of lubricating grease on cable.

18. Pull cable and buckle carrier from rail.

Installation

1. Place new rail on bench with outboard side facing up.





2. Install buckle carrier onto cable. See Figure 10.

3. Install cable assembly into new rail. Make sure the red release button on the buckle carrier is facing upward. Align cable guide with rail (cable will only go into rail with guide in the correct position).

4. Slide buckle carrier forward until locking tab engages rail.

5. Install new roll pin.

6. Position the rail and motor assembly in the vehicle and install the three (3) rail upper mounting bolts. Tighten the bolts to 38-78 N-m (28-58 lb-ft).

7. Install the rail upper mounting screw.

8. Install the two (2) rail side mounting bolts. Tighten the bolts to 38-78 N-m (28-58 lb-ft).

9. Install the two (2) cable retaining capscrews.

10. Connect the motor electrical connector.

11. Install the three (3) motor mounting bolts. Tighten the bolts to 38-78 N-m (28-58 lb-ft).

12. Connect the front limit switch electrical connector.

13. Install the quarter trim panel. Refer to appropriate Service Manual.

14. Install the A to B-pillar trim panel. Refer to appropriate Service Manual.

15. Attach the shoulder belt to the buckle carrier.

16. Connect the battery negative cable, then remove the memory saver.

17. Check the passive restraint system for proper operation.