Pickup Box Outer Side Panel Replacement Weld-on

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

1. Remove the box assembly. Refer to Pickup Box Replacement in Body Rear End.
2. Remove the endgate. Refer to Endgate Replacement in Body Rear End.
3. Remove the wheelhouse liner.
4. Remove the tail lamp. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement in Lighting Systems.
5. Repair as much of the damage as possible, according to factory specifications.
6. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
7. Note the number and location of all spot welds to be drilled out for installation of the service part.



8. Locate and drill out the spot welds on the front of the panel.



9. Locate and drill out the spot welds in the wheelhouse.



10. Locate and drill out the spot welds in the tail lamp pocket.



11. Locate and drill out the spot welds on the upper rail.



12. Remove the side panel.

1. Drill 8-mm (5/16-in) plug weld holes in the service part as noted.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating, P/N 05916 or equivalent to all mating surfaces.



4. Position the service part onto the bed assembly.



5. Plug weld the upper rail.



6. Plug weld the tail lamp pocket.



7. Plug weld the wheelhouse.



8. Plug weld the front of the panel .
9. Clean and prepare all welded surfaces.
10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint Coatings.
11. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems in General Information.
12. Install the wheelhouse liner.
13. Install the tail lamp. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement in Lighting Systems.
14. Install the endgate. Refer to Endgate Replacement in Body Rear End.
15. Install the box assembly. Refer to Pickup Box Replacement in Body Rear End.

Pickup Box Outer Side Panel Replacement Bond-on

Important: This adhesive bonding procedure repreents one manufacturer's installation application. Other manufacturers' procedures may vary, including MIG welding in some areas of the repair. Always follow the system manufacturer's instructions for application, handling, and curing.

Important: Before you begin the repair, refer to Metal Panel Bonding for proper adhesive preparations and general information.

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

1. Remove the box assembly. Refer to Pickup Box Replacement in Body Rear End.
2. Remove the endgate. Refer to Endgate Replacement in Body Rear End.
3. Remove the wheelhouse liner.
4. Remove the tail lamp. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement in Lighting Systems.
5. Repair as much or the damage as possible, according to factory specifications.
6. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
7. Note the number and location of all spot welds to be drilled out for installation of the service part.



8. Locate and drill out the spot welds on the front of the panel.



9. Locate and drill out the spot welds in the wheelhouse.



10. Locate and drill out spot welds in the tail lamp pocket.



11. Locate and drill out spot welds on the upper rail.



12. Remove the side panel.

1. Grind the surface of the bed assembly mating flanges to bare steel. Do not damage the corners or thin the metal during the grinding process.



2. Grind the mating flanges of the service side panel to remove the E-coating. Do not damage the corners or thin the metal during the grinding operation.
3. Clean the mating surfaces.




Important: The adhesive has a 40-50 minute working time. Do not allow the adhesive to cure prior to installing the service side panel.

4. Apply a 3 to 6-mm (1/8 to 1/4-in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent, to both of the mating surfaces.



5. Using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare metal to ensure corrosion protection.



6. Apply a 9 to 13-mm (3/8 to 1/2-in) bead of metal panel bonding adhesive GM P/N 12378567 (Canadian P/N 88901675) or equivalent, to the mating surface of the service side panel.




Important: Do NOT pull the panels apart after you have joined the panels together. Slide the panels against each other to realign the panels.

7. Position the service side panel to the bed assembly.
8. Clamp the service side panel into position.
9. Using lacquer thinner remove the excess adhesive from the bed side panel area.
10. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
11. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
12. Install the wheelhouse liner.
13. Install the tail lamp. Refer to Tail Lamp Assembly and /or Backup, Sidemarker, Stop, Turn Signal Bulb Replacement in Lighting Systems.
14. Install the endgate. Refer to Endgate Replacement .
15. Install the box assembly. Refer to Pickup Box Replacement .