SAIL PANEL REMOVAL & REINSTALLATION - METHOD #2
(courtesy of Alan Ritter, St. Louis, MO)
Note: Jack Gunsett has some photos of this method at this link:
http://www.frontiernet.net/~jgunsett/SPReplace.htmFor this method of sail panel removal you need access to the inside of the space frame. To do this you move the rear interior trim piece so it is out of your way and remove a single 11 mm (7/16") speed nut from the post that holds the center bottom of the sail panel to the space frame. You then lift OUT on the front part of the frame so the stud clears the space frame and press the frame toward the rear of the car. Pressure plus a quick smack or two with your hand will pop the rear edge free from the clips, which you can then remove by prying, but from the forward part, where the paint is going to be covered by the sail panel.
Removal is a modest pain.
Put seat full forward, seat back tipped all the way forward.
Remove 1 Phillips screw from interior trim piece at the door frame.
Remove shoulder belt pivot (#47 Torx)
Loosen interior trim by pulling forward and bend it inward out of your way. (Not necessary to remove totally)
You'll see a 3/4" hole in the B pillar. About 3" inside this hole is a 11 mm sheet metal nut which holds the stud from the quarter panel window. You'll need a 6" extension on your ratchet, and it's very difficult to find the nut because it's at an awkward up angle from where the hole is. Find it with your finger, remember where, then grope with the socket until you connect. If you have a 11 mm DEEP socket, much better (or a 7/16" nut driver). The stud is pretty long for a standard socket. And DO NOT drop the socket unless you want a mysterious rattle for the rest of your life. [There is an access hole at the base of the B pillar if you do drop the socket.]
Remove the 11 mm (7/16") nut, being VERY careful NOT to drop it when you pull the socket back through the hole.
Walk around to the outside of the car. Spring the quarter panel window about 1" outward at the front edge, JUST ENOUGH so the stud clears the hole in the B pillar.
Shove the quarter panel window BACK towards the REAR of the car, and it'll pop off the two snap-fit clips that hold the rear edge. You may find this step to be counter-intuitive, but it works.
To reinstall the window, you'll need to CAREFULLY pry out the two snap fit clips from the B pillar and pre-install them in their receptacles at the rear edge of the quarter panel window. Align them with the holes in the sheet metal and smack them home with the heel of your hand. The first time you do this, you'll notice you left something out of alignment where the window engages under the rain gutter and you'll have to take it off again and start over.
Then reverse the process above, reinstalling the sheet metal nut and putting the interior back together.
Also, there's a nylon snap fit that holds the top edge of the interior trim to the B pillar. CAREFULLY pry this out of the B pillar and pre-install it in its hole in the panel BEFORE you try to reinstall the panel.
Clear as mud???
This process really is a pain, but once you've done it a couple of times, everything EXCEPT the nut hidden in the B pillar is a piece of cake.