Chevrolet Silverado / GMC Sierra. Service manual — part 1299

Fig. 111: Plug Welding Pickup Box Front Panel
Courtesy of GENERAL MOTORS CORP.

4. Plug weld into position.

5. Clean and prepare all welded surfaces.

6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion

Treatment and Repair .

7. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems .

8. Install the pickup box assembly. Refer to Pickup Box Replacement .

PICKUP BOX REPLACEMENT - SIDE

Description

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.

Removal Procedure

CAUTION: Refer to Approved Equipment for Collision Repair Caution .

2008 Chevrolet Silverado 1500

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra &

Silverado

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 .

Fig. 112: Drilling Out Spot Welds
Courtesy of GENERAL MOTORS CORP.

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

2008 Chevrolet Silverado 1500

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra &

Silverado

Fig. 113: Drilling Out Spot Welds On Front Bed Panel
Courtesy of GENERAL MOTORS CORP.

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

2008 Chevrolet Silverado 1500

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra &

Silverado

Fig. 114: View Of Cross Sill
Courtesy of GENERAL MOTORS CORP.

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

IMPORTANT: Structural adhesive is used to bond the front stake pocket reinforcement

to the mating cross sill.

2008 Chevrolet Silverado 1500

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra &

Silverado