Chevrolet Silverado / GMC Sierra. Service manual — part 1300

Fig. 115: View Of Damaged Side Panel
Courtesy of GENERAL MOTORS CORP.

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

bare steel.

IMPORTANT: Before you begin the repair, refer to Metal Panel Bonding for proper

adhesive preparation and general information.

2008 Chevrolet Silverado 1500

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

Silverado

Fig. 116: Applying Metal Panel Bonding Adhesive
Courtesy of GENERAL MOTORS CORP.

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 allow the adhesive to cure prior to installing the service side panel.

2008 Chevrolet Silverado 1500

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

Silverado

Fig. 117: View Of Side Panel
Courtesy of GENERAL MOTORS CORP.

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

IMPORTANT: Do NOT pull the panels apart after you have joined the panels together.

Slide the panels against each other to realign the panels.

2008 Chevrolet Silverado 1500

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

Silverado

Fig. 118: Plug Welding New Side Panel
Courtesy of GENERAL MOTORS CORP.

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 .

PICKUP BOX OUTER SIDE PANEL REPLACEMENT (BOND-ON)

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