GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 HUMMER 🢒 2009 🢒 H3 🢒 Body Repair 🢒 Collision Repair 🢒 Pickup Box Replacement - Side

Removal Procedure

    Warning: Refer to Approved Equipment for Collision Repair Warning 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. Object Number: 2141941 Size: SH
  5. Locate and drill out spot welds along lower weld flange at bed floor.

    6. Object Number: 1306025 Size: SH
  6. Locate and drill out the spot welds that attach the cross sills to the sill extensions, tie down reinforcements and the rear post to the rear cross sill.

    7. Object Number: 2141947 Size: SH
  7. Locate and drill out all remaining spot welds including along the front bed panel.

    8. Object Number: 2141949 Size: SH
  8. Remove the side panel.

Installation Procedure
  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.

    4. Object Number: 2141952 Size: SH
  4. Position the service part on to the bed assembly.
  5. Measure for proper alignment of liftgate.

    6. Object Number: 2141956 Size: SH
  6. Plug weld as necessary.
  7. Clean and prepare all welded surfaces.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
  9. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems.
  10. Install all related panels and components.
  11. Install the box assembly. Refer to Pickup Box Replacement.