For 1990-2009 cars only
Removal Procedure
- Remove the box assembly. Refer to Pickup Box Replacement.
- Remove all related panels and components.
- Repair as much of the damage as possible, according to factory specifications.
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Locate and drill out spot welds on the inside of the panel.
- Locate and drill out the spot welds on the lower wheelhouse panel and the lower rear post to the rear sill.
- Locate and drill out the spot welds that attach the cross sill to the sill extension.
- Remove the side panel.
Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.
Installation Procedure
- Drill 8-mm (5/16-in) plug weld holes in the service part as noted.
- Prepare all mating surfaces as necessary.
- Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
- Position the service part on to the bed assembly.
- Plug weld inside of the service part.
- Plug weld the lower wheelhouse and the lower rear post to the rear sill.
- Plug weld cross sill to the sill extension.
- Clean and prepare all welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems.
- Install all related panels and components.
- Install the box assembly. Refer to Pickup Box Replacement.
