ASI Resolution - Availability of Pickup Box Reinforcements to Accomodate Aftermarket Accessory Tool Box Installation

This bulletin is being revised to add the 2006 model year, installation procedures and to announce the availability of the reinforcement kit. Please discard Corporate Bulletin Number 04-08-66-019 (Section 08 - Body and Accessories).

Some customers may want to install an aftermarket hanging toolbox in the front of the pickup box.

This bulletin is to inform dealers that if a customer wants to have a hanging toolbox installed in the front of the pickup box, a reinforcement kit MUST be installed prior to installation of the toolbox in order to avoid possible damage to the pickup box. Any load such as a toolbox or cap and the like on the pickup bed rails will require this reinforcement kit.

A pickup box reinforcement kit, P/N 15833028, has been released and is now available. This kit will contain the reinforcements and hardware necessary for toolbox installation.

Use the following service procedure as a guide to install these reinforcements.

Important: The reinforcements must be installed before adding a toolbox. After the reinforcements have been installed, follow the instructions supplied with the toolbox.

Pickup Box Front Reinforcement Installation

Important: The horizontal surfaces of the reinforcements must be flush to the horizontal surface of the pickup box top rail. Use a clamping tool when positioning the reinforcements onto the top rail to ensure flushness to the outer panel.

1. Place the front L-shaped reinforcements into position on the front top of the pickup box. For vehicles equipped with an over the rail bedliner or bed rail protectors, these accessories should be removed with the aid of an assistant prior to installing these reinforcements.
2. Using the reinforcement as a template, mark the holes necessary for drilling.
3. Remove the front reinforcements.

Important: Use a block of wood and/or a drill stop for drill through protection in order to protect the back of the cab while drilling.

4. Drill two 13.5 mm (17/32) (0.54 in) holes per side into the box section of the front panel.
5. Drill 7.5 mm (19/64) (0.30 in) holes into the weld flange of the side outer panel.
6. Apply anti-corrosion material to the drilled holes as necessary per the GM 4901M-D-2006 (English) or 4901M-D-F2006 (French) Approved Refinish Materials booklet. The information for the 2006 GM Approved Refinish Materials booklet will now be online at the GMGOODWRENCH WEB SITE ONLY*. Printed books have been discontinued. Steps to the site are as follows:

•	Go to www.gmgoodwrench.com.

•	Select and Click on GM Collision Parts from the drop down box in the center of the page.

•	Click on GM Technical Repair Information from the middle of the page.

•	Click on Paint Shop from the top bar of the page.

•	*In Canada, the 2006 GM Approved Refinish Materials booklet is also available on the GM infoNET under the Service and Body tab.

7. Place the front reinforcements back onto the box, lining up the drilled holes.
8. Install the large shoulder (M8) bolts (2 per side) into the reinforcement and front panel and the small (M6) bolts (3 per side) into the reinforcement and side outer panel with the nuts.

Tighten

•	Tighten the M8 bolts to 25 N·m (18 lb ft).

•	Tighten the M6 bolts to 9 N·m (79 lb in).

9. Remove all metal shavings from the pickup box after installation.
10. Install the bedliner and rail protectors if equipped with the aid of an assistant. The bedliner or bed rail protectors may need to be trimmed in order to obtain the necessary clearance for the reinforcements.