8 19 04 1st Copy Genuine GM Parts

8 19 04 1st Copy Genuine Gm Parts-Free PDF

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4 Locate the two die marks on the damaged frame,rail The die marks are located 302 mm 11 7 8 in. rearward from the front frame rail bumper,bracket on the top and bottom side of each rail. Important Line up the masking tape with the point of. each die mark arrow as shown,5 Apply masking tape over the die marks and down. each frame rail side as shown for the cut location. Important The tape edge facing the rear of the, vehicle is the proper cut location The cut location is. not to exceed 302 mm 11 7 8 in of the front,frame section.
6 Cut the damaged frame rail at the rear edge of,the tape line using a reciprocating saw or. equivalent as shown,2 2 Frame Procedures,7 Remove the damaged frame section. Installation Procedure, 1 Grind the existing frame rail sectioning location to. a 45 degree angle, 2 Prepare all of the attaching surfaces as necessary. Frame Procedures, 3 Position the service frame section to the existing.
frame and clamp in place,Frame Procedures 2 3,Important Inspect the frame measurements. three dimensionally to ensure proper position of the. service frame prior to welding Refer to Dimensions. 4 Continuous weld the upper and lower horizontal,joints from corner to corner. 5 Continuous weld the inner and outer vertical joints. from corner to corner,6 Clean and prepare all of the welded surfaces. 7 Apply the sealers and anti corrosion materials to. the repair area as necessary Refer to,Anti Corrosion Treatment and Repair. 8 Install all of the related panels and components. Caution Refer to Battery Disconnect Caution,on page 1 1.
9 Connect the negative battery cable,10 Enable the SIR system Refer to SIR Disabling. and Enabling Zones on page 1 118,2 4 Frame Procedures. Frame Sectioning Front Full Frame,Mid size utility 2002 current. except S T models,Removal Procedure,The re designed frame assembly for the new S T. Utility is a mild steel hydroformed frame assembly A. front frame service section consisting of the left. and right frame ends body and radiator support, mounting brackets and front connecting cross tube is.
available If damage permits locate and cut off the. front 420 mm 161 2 in portion of the frame using the. die mark indicators as a guide The front and rear,body mounts radiator support mounts steering gear. and transmission cross member can be ordered,and replaced separately. 1 Remove all of the related panels and components,including the front bumper assembly. Frame Procedures,2 Locate the 2 die marks on each frame The die. marks are located 420 mm 161 2 in rearward,from each front frame rail end on the top.
and bottom side of each rail,Frame Procedures 2 5, Important Line up the masking tape with the point of. each die mark arrow,3 Apply masking tape over the die marks and down. each frame rail side as shown for the cut location. Important The tape edge facing the rear of the, vehicle is the proper cut location The cut location is. not to exceed 420 mm 161 2 in of the front frame, 4 Cut each frame at the rear edge of the tape line. using a reciprocating saw or equivalent as shown,5 Remove the damaged frame section.
2 6 Frame Procedures,Installation Procedure, 1 Grind the existing frame rail seam to taper seam. at a 45 degree angle, 2 Prepare all of the attaching surfaces as necessary. 3 Apply the weld thru primer to all of the welded, 4 Position the service frame section to the existing. frame and clamp in place,Frame Procedures,Important Verify the frame measurements. 3 dimensionally to ensure proper position of the,service frame.
5 Continuous weld the upper and lower horizontal,joints from corner to corner. Frame Procedures 2 7,Important Verify the frame measurements. 3 dimensionally to ensure proper position of the,service frame. 6 Continuous weld the inner and outer vertical joints. from corner to corner,7 Clean and prepare all of the welded surfaces. 8 Install all of the related panels and components. Rail End Crush Cap Replacement Front,Full size pickup 1999 and.
utility 2000 current,Removal Procedure,Important The redesigned frame of the 1500 model. C K pickup and C K Utility incorporates hydroformed. technology There is a replaceable hydroformed, energy absorbing crush cap at the front of the frame. 1 Remove all of the related panels and the,components. Important If the crush cap 1 is bent or damaged in. any way replace the crush cap,2 Visually inspect the damage Use 3 dimensional. measuring in order to restore all of the damage,rearward of the crush cap 1 to the factory.
specifications,2 8 Frame Procedures,Important Do not damage the rail. 3 Remove the core support mounting bracket 2,4 Locate the brake line attachment hole 1 on. the top of the rail Measure forward 155 mm,6 1 8 in This is the cut line 2. 5 Scribe a line 360 degrees around the frame rail, Important Use caution to not damage the cross tube. 6 Remove the crush cap at the cut line and the,forward edge of the cross tube.
7 Grind the remaining weld off of the cross tube 1. where you removed the damaged crush cap,Frame Procedures. Installation Procedure, 1 Drill 4 plug weld holes 2 at the top and 2 at the. bottom 13 mm 1 2 in from the cut line and,50 mm 2 in apart on the existing frame rail 1. 2 Prepare all mating surfaces as necessary,3 Apply 3M Weld Thru Coating P N 05916 or. equivalent to all mating surfaces,Frame Procedures 2 9.
The replacement bumper bracket 2 is a bolt on,component that must be ordered separately. Retain a gap of 11 2 times the metal thickness at,the butt joint 1 when attaching the service part. to the vehicle,4 Install and position the replacement crush cap. using 3 dimensional measuring, 5 Tack weld the part into position at the initial plug. weld holes,6 Inspect the service part for proper dimensions.
7 Stitch weld along the entire sectioning joint Make. 25 mm 1 in welds along the seam with 25 mm,1 in gaps between. 8 Complete the stitch weld,9 Clean and prepare the welded surfaces. Important Prior to refinishing refer to GM 4901M, 383506 Refinish Manual for recommended products Do. not combine paint systems Refer to paint,manufacturer s recommendations. 10 Apply approved anti corrosion primer,11 Position the new core support mounting bracket.
Weld the bracket in place according to the,specified dimensions. 12 Apply the sealers,13 Refinish the welded surfaces as necessary. 14 Replace the related panels and the components,Frame Module Replacement Rear. Full size pickup 1999 current,Removal Procedure, Important Perform all of the steps on both of the rails. for complete module replacement,1 Remove all of the related panels and the.
components, 2 Visually inspect all of the damage forward of the. rear module Use 3 dimensional measuring in,order to restore the damage to the factory. specifications,3 Separate the center and the rear module at the. factory stitch weld 1 with a die grinder or an,appropriate tool. 4 Pry the lower edge of cross tube bracket down 2, in order to allow the rear module to separate from.
the center module,5 Remove the damaged rear module. 2 10 Frame Procedures,Installation Procedure,Important Monitor the specified dimensions by. frequently performing 3 dimensional measuring,throughout the procedures. 1 Prepare all mating surfaces as necessary,2 Apply 3M Weld Thru Coating P N 05916 or. equivalent to all mating surfaces, 3 Install and position the replacement module using.
3 dimensional measuring, 4 Restore the bracket flange 2 for a flush fit to the. new service part,5 Tack weld the rear module into position Inspect. the service part for the proper dimensions,6 Stitch weld the entire sectioning joint. Important Prior to refinishing refer to GM 4901M,Refinish Manual for recommended products Do. not combine paint systems Refer to paint,manufacturer s recommendations 383485.
7 Clean and prepare the welded surfaces,8 Apply approved anti corrosion primer. 9 Apply the sealers,10 Refinish the welded surfaces as necessary. 11 Install all of the related panels and the,components. Frame Procedures,Bracket Replacement Front Bumper,2500 Full size pickup 1999 current. 1 Remove all related panels and components,2 Remove the damaged bumper bracket.
3 Visually inspect the frame and restore all damage. to factory specifications using 3 dimensional, Important If the vehicle is equipped with tow hooks. discard original fasteners,4 Align the replacement bracket lower bolt holes. with tow hook mounting locations and install the,bolts 1 supplied. Frame Procedures 2 11, 5 Align the front edge of bracket with front edge of. frame and mark upper bolt locations 1 on frame,6 Rotate the bracket forward and drill 13 mm.
1 2 in holes in frame at upper bolt locations,7 Rotate the bracket back into position. Notice Refer to Fastener Notice on page 1 1,8 Install the fasteners supplied. Tighten the torque bracket fasteners to,70 N m 52 lb ft. 2 12 Frame Procedures,Bracket Replacement Front Bumper. 1500 Full size pickup 1999 and,utility 2000 current.
1 Remove all related panels and components,2 Remove damaged bumper bracket. Important Do not remove any material from end of,frame rail. 3 Position the service template on the end of the,frame rail Use 3M s Repositionable Adhesive or. equivalent,4 Drill three 13 mm 1 2 in holes at locations. indicated on template, Important Prior to refinishing refer to the Publication.
GM 4901M D 2000 GM Approved Refinish Materials,for recommended products Do not combine paint. systems Refer to paint manufacturer s,recommendations. 5 Apply approved anti corrosion primer to bare,metal surfaces. 6 Position replacement bumper bracket,Notice Refer to Fastener Notice on page 1 1. 7 Install the bolts,Frame Procedures,Tighten the bolts to 50 N m 37 lb ft.
Rail End Replacement Rear,Full size utility 2000 current. Removal Procedure, The service assembly for the left and the right rear. frame rails is pre sleeved mild steel hydro formed. parts The assembly includes the body support,mounting bracket a trailer hitch and rear bumper. mounting holes,Frame Procedures 2 13,Important The position of the rear cross member 1. varies upon the wheel base of the vehicle This,procedure applies to all vehicles.
Caution Refer to Approved Equipment for,Collision Repair Caution on page 1 1. Caution Refer to Battery Disconnect Caution on,Caution Refer to Collision Sectioning Caution on. 1 Disconnect the negative battery cable,2 Remove all of the related panels and components. 3 Repair as much of the damage as possible to,factory specifications. 4 Locate the sectioning location by measuring,13 mm forward from the shipping slot 1 or.
330 mm forward of the frame rail end Scribe a,line around the rail. 2 14 Frame Procedures,5 Using a cut off wheel or equivalent remove the. weld which attaches the rear cross member to the,damaged frame rail. 6 Move the cross member clear of the damaged,frame rail. Frame Procedures,Important Align the edge of the masking tape with.
the sectioning location, 7 Apply masking tape next to the sectioning location. and around the frame as shown,Frame Procedures 2 15. Utility is a mild steel hydroformed frame assembly A front frame service section consisting of the left and right frame ends body and radiator support mounting brackets and front connecting cross tube is available If damage permits locate and cut off the front 420 mm 161 2 in portion of the frame using the die mark indicators as a

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