This procedure shows illustrations for the 6.6L box. The 5.8, 8.0, and dually pickup boxes are similar. This procedure may be used for all pickup box sizes.

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

1. Remove the box assembly. Refer to Pickup Box Replacement .
2. Remove all related panels and components.
3. Repair as much of the damage as possible, according to factory specifications.
4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .



5. Locate and drill out spot welds on the inside of the panel.



6. Locate and drill out the spot welds along the front bed panel.




Important: Structural adhesive is used to bond the front stake pocket reinforcement to the mating cross sill.

7. Use a heat gun or a chisel to separate the stake pocket reinforcement from the cross sill (1).



8. 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 GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .

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

4. Grind the surface of the pickup box cross sill and the front stake pocket reinforcement mating flanges to bare steel.




Important: Do not allow the adhesive to cure prior to installing the service side panel.

5. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive to both of the mating surfaces.
6. 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.
7. Apply three 9-13 mm (3/8-1/2 in) beads of metal panel bonding adhesive as shown.




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

8. Position the service side panel to the bed assembly.



9. Plug weld as necessary
10. Clean and prepare all welded surfaces.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
12. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems .
13. Install all related panels and components.
14. Install the box assembly. Refer to Pickup Box Replacement .