i recently took my 2004 c5 Z06 mil yellow to have oil changed and the shop that did it crushed my rocker panels with there 2 post lift. i filed a law suit against them and fighting them as we speak. i need the complete step by step instructions on how to replace the rocker panels. my local chevy dealership wants $6,139.16 to fix my car. in which i have no problem paying because i will be collecting from my law suit. according to chevy the roof has to come off and when removed the roof will need to be replaced. i just want my car fixed dont care how much it cost!!!!!! and from what ive looked up they only made 629 mil yellow Z06 vettes in 2004 plus my car has 21,000 miles

 

pics??

no insurance coverage by you or the shop?

 

Here's the procedure for replacement of the rocker panels,NOTE no mention of the roof removal

Door Opening Frame Replacement - Side
Tools Required
J 42058 Frame Adapter Clamp

Removal Procedure

Notice
The frame rails and bumper impact bars must be serviced as required, and returned to three-dimensional coordinates before any SMC repairs are attempted.


Visually inspect for damage to the frame rails or wheelhouse mounting areas. Restore as much of the damage as possible to specifications using three-dimensional measuring procedures. Use J 42058 if vehicle pulling and straightening are required.
Remove all panels and components to gain access to door side frame. The door side frame can be removed if the quarter panel is loosened from it. This may include removal of the following components:
Door
Quarter panel
Quarter inner splash shield
Remove latch striker closeout cover and striker.
Remove the trim screws that attach the side door frame panel to the rail. These screws must be re-installed to secure the service panel in place until the adhesive cures.

Important
Make sure the fuel inlet is sealed before proceeding with repair procedure.


Use caution along the underside of the vehicle when applying heat not to de-bond the floor panels from the frame rail.



Apply heat and pry to break bond along area (1).
Installation Procedure
Remove all remaining adhesive, and scuff all bonding surfaces to ensure proper adhesion.
Clean and prepare all bonding surfaces prior to SMC panel installation. Refer to Plastic Panels in Plastic Panel Information and Repair.
Prime all bare metal surfaces with PPGs DP90, or an equivalent epoxy anti-corrosion primer. Do not top-coat any bonding surface.
Temporarily fit the side door opening assembly to ensure proper fit and alignment with adjacent panels.
Remove panel assembly and apply a consistent bead of adhesive (1) to the front body hinge pillar and top surface of rail (2) and to all areas originally bonded, except for bottom side of rail.
The bead should be 10 mm (13/32 in) diameter.



This area is bonded after the side door opening assembly is installed.



Install assembly using original screws in factory locations. The screws are necessary to secure the service part until the adhesive cures.

Important
Ensure that the foam seal on the front body hinge pillar portion of the side door opening panel makes contact with the front hinge pillar.



Important
Use only approved adhesives. Refer to Repair Materials - Rigid Plastic Part in Plastic Panel Information and Repair.


Apply adhesive to inner edge of rocker and clamp in place until adhesive cures. Standoffs in part must fit flush against bottom of rail.
Remove excess adhesive squeeze-out and allow to cure.
Prime bare metal areas with PPGs DP90, or an equivalent epoxy anti-corrosion primer. Do not combine paint systems. Always refer to paint manufacturer's recommendations.
Install all related panels and components.

 

I see no reason why the roof has to be removed to replace the rocker panel. I think your dealer is in regards to that. The rocker panels are glued onto the car and it is very difficult to get them off in one piece, and finding OEM replacements is very difficult. Perhaps one of the forum used parts vendors would have access to a complete rocker panel or at least one that can be spliced into the existing one to replace the damaged area. The latter is not the preferred way to go IMO, but it may be all that is available.

Good luck settling this with the shop that did the damage and in getting the car repaired.

 

For those that may be unaware, you can't just lift the Corvette anywhere underneath. You must use jacking pucks if you are lifting it from the sides. Here are pics that explain vehicle lifting and jacking locations.

 

Can I ask why in the world you took your C5 to a random shop without knowing all the specifics regarding jacking? At the least you should of had a set of jacking pucks on hand (snapped in prior to going) or ensure the shop knew of proper positioning of the posts. If they didn't then you drive away.

As Vetteman Jack mentioned the roof skin does not need to come off. The roof skin is separated from the rear quarter at the body seam and thus the rear quarter and lower rocker can be removed as assemblies without removing the roof. The biggest issue as he mentioned is going to be the rockers themselves. They never tend to come off as one piece and they're bonded in the same way that the front fender liners are bonded to the chassis. It's a very specific way the rockers have to go on when they're bonded, otherwise they will mess up visually how the door and rear quarter lines up with the body. It's a real PITA.

You're probably going to pay a good chunk for used replacements if you can get a set in one piece.

I'm not sure why you've pursued litigation against the shop unless your initial actions with them proved fruitless. If they are insured and claimed they weren't going to deal with you you probably should have went through your own insurance, who would have then went after them for the payout. I also would say it's probably a mistake you went to a Chevrolet dealer. What you should have done is contacted the dealer's service department and see who they authorize to service body work on Corvettes. All really big Chevrolet dealers, if they don't perform body work on-site, are required to have their utilized body shop have a Corvette-specific technician who is the only person that works on Corvettes. When I had some work on my car performed a few years back my local dealer referred me directly to the technician himself, whom I took the car to and had the damage accessed. He was a career body man (he started when C5s were still new) and having the experience knew exactly what to look for and how to handle it.

 

In all fairness to the shop estimating the bodywork. If they were to do it 100% by the book, yes the roof does need to be removed to get to the 5 (2 drivers & 3 passenger) hidden screws that hold down the rear quarters. Then the rocker panels can be removed. So two different ends of the spectrums. One shop was not very cautious and the other is being probably over cautious. No doubt because of the first shops botch up.

 

One thing I wanted to mention is that there are custom replacement rocker panels with rear brake scoops that are made by Breathless Performance in Florida. This might help your situation when it comes to finding replacements. Not an easy job to install but it might help expedite your repairs. They are kind of like a custom Z06 brake air scoop.