Pickup Box Assembly Replacement - Side

Pickup Box Assembly Replacement - Side

Removal Procedure

Caution: Refer to Approved Equipment for Collision Repair Caution in Service Precautions.

1. Remove the box assembly.
2. Remove the end gate.
3. Remove the wheelhouse liner.
4. Remove the tail lamp.
5. Repair as much of the damage as possible, according to factory specifications.
6. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
7. Note the location of all spot welds to be drilled out.




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




9. Locate and drill out the spot welds on the lower wheelhouse panel and the lower rear post to the rear sill.




10. Locate and drill out the spot welds that attach the cross sill to the sill extension.




11. 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 3M Weld-Thru Coating, P/N 05916 or equivalent to all mating surfaces.




4. Position the service part on to the bed assembly.




5. Plug weld inside of the service part.




6. Plug weld the lower wheelhouse and the lower rear post to the rear sill.




7. Plug weld cross sill to the sill extension.
8. Clean and prepare all welded surfaces.
9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
10. Paint and repair the area.
11. Install the wheelhouse liner.
12. Install the tail lamp.
13. Install the box assembly.
14. Install the end gate.