Truck Bed: Service and Repair

Pickup Box Replacement - Side

Removal Procedure

Warning: Refer to Approved Equipment for Collision Repair Warning (Approved Equipment for Collision Repair Warning).

1. Remove the box assembly. Refer to Pickup Box Replacement (Service and Repair).
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. Locate and drill out spot welds on the inside of the panel.




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




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




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. 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 ().
10. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems (Basecoat/Clearcoat Paint Systems).
11. Install all related panels and components.
12. Install the box assembly. Refer to Pickup Box Replacement (Service and Repair).