Body Rear End

S p e c if ic a t io n s

Fastener Tightening Specifications

Specification
Application Metric English
Bedliner Screws 2 N-m 181b in
Body Side Hinge Bolts (Pickup) 27 N-m 201b ft
Endgate Bumper to Endgate Screws (Utility) 3 N-m 271b in
Endgate Latch to Endgate Bolts (Utility) 10 N*m 891b in
Endgate Liner Screws 2 N-m 18 lb in
Endgate Side Hinge Bolts (Pickup) 27 N-m 20 Ib ft
Endgate Striker Bolts (Pickup) 30 N-m 22 Ib ft
Endgate Window Assembly Hinge Nuts (Utility) 23 N-m 17 1b ft
Endgate Window Assembly Striker Bolts (Utility) 10 N-m 891b in
Jack and Tool Stowage Container Nut 5Nm 44 Ib in
Latch Operating Handle Bolts (Pickup) 25 N-m 181b ft
Latch Operating Handle to Endgate Bolts (Utility) 4 N-m 35 Ib in
Latch to Endgate Bolts (Pickup) 30 N-m 22 Ib ft
Latch Assembly Cover to Endgate Bolts (Utility) 15 N-m 11 Ib ft
Latch Assembly to Endgate Bolts (Utility) 15 N-m 11 Ib ft
Support Cable to Body Bolts (Utility) 29 N-m 22 Ib ft
Support Cable to Endgate Bolts (Utility) 3 N-m 27 Ib in
Striker to Body Bolts (Utility) 63 N-m 47 Ib ft
Strut Stud to Body Bolts (Utility) 17 N-m 131b ft
Strut Stud to Endgate Window Assembly (Utility) 17 N-m 13 1b ft
Torque Rod Bracket Bolts (Utility) 15 N-m 11 Ib ft
Trim Panel to Endgate Screws (Utility) 2 N-m 181b in

GM SPO Group Numbers

plication GM SPO Group Number
Bedliner 17.090
Endgate Liner 17 185
Garnish Molding — Rear 16 166
Jack 8 820
Jack and Tool Stowage Container 8.821
Jack and Tool Stowage Tray 8.821
Rear Door 16.160
Rear Door Check Link 16.437
Rear Door Garnish Molding 16.166
Rear Door Hinge 16.320
Rear Door Latch Striker — Lower 16.320
Rear Door Latch Striker — Upper 16 335
Rear Door Lock Actuator 16.263
Rear Door Lock Cylinder Kit 16.328
Rear Door Lock Cylinder Retainer 16.328
Rear Door Lock Cylinder Rod 16.332
Rear Door Lock Lever 16.341
Rear Door Outside Handle 16.350
 GM SPO Group Numbers (cont’d)
Application GIVI SPO Group Mum!
Rear Door Outside Handle Rod 10.341
Rear Door Trim Panel 16.165
Rear Door Trim Panel Lace 16,742.
Rear Door Upper Molding 17.215
Rear Door Water Deflector 16,160
Rear Door Weatherstrip 16.183
Rear Door Weatherstrip .. 16.227
Rear Roof Drip Molding • 6.8-'2

S c h e m a t ic a n d R o u t in g D ia g r a m s

Body Rear End Schematic References

Section Number - Subsection
Reference on Schematic Name
Ground Distribution Cell - 14 8 - Wiring Systems
Power Distribution Cell - 10 G Wiring System?■
Body and Accessories_________________________________________________________________________
466784
C o m p o n e n t L o c a to r

Body Rear End Components

Name Location Locator View inector End View
P ow er and Grounding Power and Grounding
Under the left side of the IP, on the
Convenience Center Component Views in Connector End Views in
bulkhead
Wiring Systems Wiring Systems
Power and Grounding Power and Grounding
To the left of the IP, near the left front
IP Fuse Block Component Views in Connector End Views in
door jamb switch
Wiring Systems Wiring Systems
Body Rear End Body Rear End
Liftgate Release Motor In the right center of the liftgate
Component Views Connector End Views
In the center of the IP, to the left of Body Rear End Body Rear End
Liftgate Release Switch
the radio Component Views Connector End Views
Part of the engine harness to IP harness, Inline Harness Connector
Harness Routing Views
C100 in the left rear side of the engine End Views in Wiring
in Wiring Systems
compartment, at the bulkhead Systems
Inline Harness Connector
Behind the right side of the IP, near the Harness Routing Views
C200 End Views in Wiring
heater motor, in foam wrap in Wiring Systems
Systems
Inline Harness Connector
Harness Routing Views
C210 At the convenience center End Views in Wiring
in Wiring Systems
Systems
Inline Harness Connector
Behind the left side of the IP, near the Harness Routing Views
C298 End Views in Wiring
convenience center in Wiring Systems
Systems
Inline Harness Connector
Harness Routing Views
C301 At the left front kick panel End Views in Wiring
in Wiring Systems
Systems
Inline Harness Connector
C314 Harness Routing Views
On the left D-pillar behind the trim cover End Views in Wiring
(Suburban/Utility) in Wiring Systems
Systems
Inline Harness Connector
C450 Center rear of the vehicle under the floor Harness Routing Views
End Views in Wiring
(Suburban/Utility) between P409 and P410 in Wiring Systems
Systems
Power and Grounding
G105
On the right front side of the engine block Component Views —
(Gas)
in Wiring Systems
Power and Grounding
G105 Right Rear of the cylinder head,
(Diesel) cylinder #7 intake bolt Component Views —
in Wiring Systems
In the right rear side of the engine Harness Routing Views
P101 —
compartment, at the bulkhead in Wiring Systems
Harness Routing Views
P409 In the center rear of the body —
in Wiring Systems
Harness Routing Views
P410 At the center bottom of the endgate —
in Wiring Systems
Engine harness, approx. 7 cm (2.5 in) from
S106
EGR valve breakout, toward fuel injector — —
(7.4L)
breakout
Engine harness, approx. 20 cm (8 in) from
S107
EGR valve breakout, toward taillamp — —
(5.0L, 5.7L)
harness breakout
Engine harness, approx. 40 cm (15 in)
S107
from EBCM breakout, toward Transmission — —
(6.5L, HD)
harness breakout
Engine harness, approx. 18 cm (7 in) from
S107
EBCM breakout, toward tthe EGR harness — —
(7-4L)
breakout
 Body Rear End Components (cont’d)
Name Location Locator View Connector End View
Engine harness, approx. 5 cm (2 in) from
S147
EGR valve breakout, toward taillamp — —
(Gas)
harness breakout
S147 Engine harness, approx. 4 cm (1.5 in) from
—
(Diesel) starter motor solenoid breakout
I P harness, approx. 4 cm (1.5 in) from
S264 instrument cluster breakout, toward radio — —
connectors breakout
S265 Crossbody harness, approx. 8 cm (3 in)
from LF door breakout — —-
(Suburban/Utility)
Front-to-rear body harness, approx. 12 cm
S410 (4-Door
(4.5 in) from RR door speaker breakout, — —
Utility/Suburban)
toward RR door jamb breakout

Body Rear End Component Views

Liftgate Release Motor Wiring

277193

Legend
(1) C406 (5) C450
(2) C404 (6) P409
(3) Liftgate Release Motor (7) C314
(4) P410 (8) C402
372232
 Inflatable Restraint IP Module Switch

Legend
(1) Rear Window Wiper/Washer Switch (5) Inflatable Restraint IP Module Switch
(2) Liftgate Release Switch (Pickup) / Daytime Running Lamps (DRL)
(3) Ashtray Lamp Radio Override Switch (Z56) / Auxiliary
(4) Cigar Lighter Heater Fan Switch
Body Rear End Connector End Views
Liftgate Release Motor
Liftgate Release Switch

'Connector Part •12120136 :

Connector Part 12120136 Information • 2F M/P 480 Series (BLK)
Information 4F m/P 280 Series (BLK) Circuit
Circuit Pin Wire Color No. Function
Pin Wire Color No. Function BLK/WHT 1576 Liftgate Release Motor
BRN Park Lamp Feed Transmission Mounted
BLK 150 Ground YEL 1737 Neutral Saftey Switch
Output Park/Neutral
Fuse Output - Battery
ORN 540
Type III Fuse
BLK/WHT 1576 Liftgate Release Motor
D ia g n o s t ic I n f o r m a t io n a n d P r o c e d u r e s

Endgate Window Release System Check

Step Action Normal Result(s) Abnoima] Results)*
1, Ensure the transmission is in The endgate window is released. E n d g a te W in d o w R e le a s e
PARK or NETURAL. In o p e r a tiv e
1
2. Depress the endgate window
release switch.
* Refer to the appropriate symptom diagnostic table for the applicable abnormal result.

Endgate Window Release Inoperative

Step Action Value(s) Yes No
Has the Endgate Release System Check been performed? Go to Endgate
1 Window Release
Go to Step 2 System Check

1. Disconnect C210 at Convenience Center.

2. Connect a test lamp between Convenience Center
2 cavity E5 and ground. —
3. Depress Liftgate Release Switch.
Does test lamp light? Go to Step 8 Go to Step 3
1. Connect a test lamp between Liftgate Release Switch
cavity D and ground.
3 —
2. Depress Liftgate Release Switch.
Does test lamp light? Go to Step 4 Go to Step 5
Repair open in CKT 1576 (BLK) between Liftgate Release
Switch and Convenience Center. Refer to Wiring Repairs Go to Endgate
4 in Wiring Systems. — —
Window Release
Is the repair complete? System Check
Connect a test lamp between Liftgate Release Switch
5 cavity C and ground. —
Does test lamp light? Go to Step 6 Go to Step 7
Replace Liftgate Release Switch. Refer to Accessory Go to Endgate
6 Switch Replacement — Window Release —
Is the repair complete? System Check
Repair open in CKT 640 (ORN) between Liftgate Release
Switch and l/P Fuse Block. Refer to Wiring Repairs in Go to Endgate
7 Wiring Systems. — —
Window Release
is the repair complete? System Check

1. Connect a test lamp between Liftgate Release Motor

cavity A and ground.
8 —
2. Depress Liftgate Release Switch.
Does test lamp light? Go to Step 10 Go to Step 9
Repair open in CKT 1576 (BLK) between Liftgate Release
Switch and Liftgate Release Motor. Refer to Wiring Go to Endgate
9 Repairs in Wiring Systems. — —
Window Release
Is the repair complete? System Check

1. Place transmission in Park or Netural.

10 2. Connect a test lamp between Liftgate release motor —■
cavity B and B+.
Does test lamp light? Go to Step 15 Go to Step 11
Connect a test lamp between Park/Netural Position Switch
11 C1 cavity A and B+. —
Does test lamp light Go to Step 12 Go to Step 13
 Endgate Window Release Inoperative (cont’d)
Step Action VaSue(s) Yes No
Repair open in CKT 1737 (YEL) between Lifgate Release
Motor and Park/Netural Position Switch. Refer to Wiring Go to Endgate
12 Repairs in Wiring Systems. — —
Window Release
Is the repair complete? System Check
Connect a test lamp between Park/Neutral Position Switch
13 Connector C1 cavity D and B+. —
Does test lamp light? Go to Step 16 toSL-,.
Repair open in CKT 150 (BLK) between Park/Netural
Position Switch and G105. Refer to Wiring Repairs in Go to Endgate
14 Wiring Systems. — —
Window Release
Is the repair complete? System Check
Replace Liftgate Release Motor. Go to Endgate
15 Is the repair complete? — Window Release —
System Check
Replace Park/Netural Position Switch. Go to Endgate
16 Is the repair complete? ■ — ■ Window Release —
System Check
R e p a ir I n s t r u c t io n s

Latch Replacement - Liftgate

Removal Procedure
1. Remove the trim panel . Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( P i c k u p o r U t ilit y ).
2 . Remove the latch assembly cover (1) to the
endgate bolts (2).
3. Remove the latch assembly cover and the seal .
4. Remove the lock rods from the l ock assembly.
Mark the l ocation of the latch assembly on the
endgate.
5. Remove the latch assembly (4) to the
endgate bolts.
6. Remove the latch assembly from the endgate.

264385

Installation Procedure
1. Install the latch assembly (4) and the seal (5) to
the endgate.
Align the assembly to the marks on the endgate
inner panel.
Notice: Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install the latch assembly to the endgate bolts.
Tighten
Tighten the latch assembly to the endgate bolts to
15 N-m (11 Ib ft).
3. Install the lock rods to the latch assembly.
4. Install the latch assembly cover (1).
The cover must be installed with both gates
closed for proper alignment.
5. Install the latch assembly cover to the
endgate bolts.
264385
Tighten
Tighten the cover to the endgate bolts to
15 N-m (11 Ib ft).
Install the trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( P i c k u p o r U t ilit y ) .
 Trim Panel Replacement Rear Door
(Pickup or Utility)
Removal Procedure
1. Lower the endgate.
2. Remove the trim panel to the endgate screws.
3. Remove the trim panel from the endgate.

264366

Installation Procedure
1. Install the trim panel to the endgate.
Notice: Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install the trim panel to the endgate screws.
Tighten
Tighten the trim panel to the endgate screws to
2 N-m (181b in).

Trim Panel Replacement - Rear Door

(Utility)
Removal Procedure
Tools Required
J 3 8 7 7 8 Trim Panel Remover
1. Using the J 3 8 7 7 8 , carefully pry the retainers from
the retainer seats.
Remove the trim panel from the door.
2. Remove the retainers from the trim panel.

277847
Installation Procedure
1. Install the retainers to the trim panel .
2. Install the trim panel to the door by completing the
following steps:
2.1. Align the retainers with the holes in
the door.
2.2. Carefully apply pressure to the seat
retainers.

277847

W ater Deflector Replacement

Removal Procedure
1. Remove the trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
2 . Remove the water deflector by completing the
following steps:
2.1. Using a flat-blade tool, break the bond
between the sealer and the door.
2.2. Pull off the water deflector.
Installation Procedure
1. Install the water deflector to the door.
Use waterproof tape or 3M® 777 adhesive, as
necessary.
2. Install the trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .

Jack and Tool Stowage (Suburban)

Removal Procedure
1. Remove the nut retaining the jack and tool
stowage tray.
2. Remove the jack and tools from the stowage tray.
 276961

Installation Procedure
1. Install the stud to the tool stowage tray.

276961

Notice: Refer to F a s t e n e r N o t i c e in Cautions and

I Notices.
2. Install the jack and tools into the stowage tray.
3. Install the jack and tool stowage tray nut.

276964
Jack and Tool Stowage
(Pickup and Crew Cab)
Removal Procedure
1. Remove the nut retaining the jack and tool
stowage container cover.

2. Remove the jack and tools from the stowage

container.

3. Remove the tool stowage container from the

bracket.

276954
 installation Procedure
1. I nstall the tool stowage container to the bracket.

2. Install the jack and tools into the stowage

container.

276956

Notice: Refer to F a s t e n e r N o t i c e in Cautions and

Notices.
3. Install the jack and tool stowage tray cover
and nut.
Jack and Tool Stowage (Extended Cab)
Removal Procedure
1. Remove the nut retaining the jack and tool
stowage container cover.

2. Remove the jack and tools from the stowage

container.

3. Remove the tool stowage container from the

bracket.

276957
Installation Procedure
1. Install the tool stowage container to the bracket.

2. Install the jack and tools into the stowage

container.

N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and

Notices.
3. Install the jack and tool stowage tray cover
and nut.
Jack and Tool Stowage (2 Door)
Removal Procedure
1. Remove the nut retaining the jack and tool
stowage tray cover.

2. Remove the jack and tools from the stowage tray.

3. Remove the jack and tool stowage tray.

276971
 Installation Procedure
1. I nstall the jack and tool stowage tray.

2. I nstall the jack and tools into the stowage tray.

276974

N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and

Notices.
3. I nstall the jack and tool stowage tray cover
and nut.

276969
Jack and Tool Stowage (4 Door)
Removal Procedure
1. Remove the nut retaining the jack and tool
stowage tray cover.

2. Remove the jack and tools from the stowage tray.

3. Remove the jack and tool stowage tray.

276979

Installation Procedure
1. Install the jack and tool stowage tray.
2. Install the jack and tools into the stowage tray.

276979
 Notice: Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
3. I nstall the jack and tool stowage tray cover
and nut.
Tighten
Tighten the nut to retain the jack and tool stowage
tray cover to 5 N-m (44 Ib in).

276977

Door Protector Replacement - Rear

Removal Procedure
1. Remove the protector bolts (1).
2. Remove the protector (2).

Installation Procedure
1. Install the protector (2).
2. Install the protector bolts (1).

277854
W indow Garnish Molding Replacement
Removal Procedure
1. Remove the trim panel. Refer to Trim P a n e l
R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
2. Remove the garnish mol ding screws.
3. Remove the garnish mol ding retainers.
4. Remove the garnish molding from the door.

277849

Installation Procedure
1. Install the garnish molding to the door.
2. Install the garnish molding retainers.
3. I nstall the garnish molding screws.
4. Install the trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .

277849

Door Replacement - Rear

Removal Procedure
C a u tio n : R e f e r to B a t t e r y D is c o n n e c t C a u t io n in
C a u tio n s a n d N o tic e s .
1. Disconnect the negative battery cable, as
necessary with vehicl es with power components.
2. Apply cloth-backed tape to the door and to the
body pillar.
3. Using a soft-faced hammer and locking pliers,
remove the check assembly hinge pin.
4. Using a soft-faced hammer and locking pliers,
remove the lower hinge pin.
5. Install a temporary bolt through the lower hinges
in order to hold the door in place during the
removal of the upper hinge pin.
6. Remove the upper hinge pin.
7. Remove the bolt from the lower hinge pin hole.
8. Remove the door from the vehicle.
277851
 Installation Procedure
1. I nstall the door to the vehicle.
2. Instal l a bolt through the l ower hinge pin holes.
3. Using a soft-faced hammer and a pair of locking
pliers, install the upper hinge pin with the pointed
end of the pin pointing downward.
4. Remove the temporary bolt from the lower hinge.
5. Install the jower hinge pin with the pointed end
of the pin pointing downward.
6. Remove the cloth-backed tape from the door and
the body pillar.
7. Install the check assembly hinge pin with the
pointed end of the pin pointing downward.
8. Connect the negative battery cable, as necessary.

277851

Door Adjustment - Rear

Use this procedure only when bolt-on service
replacement hinges are installed.
Tools Required
J 2 9 8 4 3 - 9 TORX® Bit (Bit Size T47)
Adjustment Procedure
1. Using the J 2 9 8 4 3 - 9 , remove the striker bolt.
2. Loosen the door hinge to the body side pillar bolts.
3. Adjust the door at the hinges in the following
directions: ~-
• Upward or downward
• Forward or rearward
• Inward or outward
4. Adjust the gap between the rocker panel and
the door.
5. Adjust the gap between the door and the roof
panel to 4.0-8.0 mm (0.16-0.31 in).
6. Adjust the gap between the rear of the door and
the rear pillar to 3.0-Z.0 mm (0.12-0.28 in).
7. Adjust the gap between the door and the fender.
8. Adjust the door so that the door surfaces are
flush with the other panels within
1.0 mm (0.04 in).
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices. »
9. Tighten the hinge bolts.
Tighten
Tighten the bolts to 35 N-m (26 Ib ft).
10. Install the door striker bolt.
Adjust the bolt in order to properly engage the
door lock.
Tighten
Tighten the bolt to 28 N-m (21 Ib ft).

277819
Endgate Replacement (Pickup)
Removal Procedure
1. Lower the endgate (3) to a horizontal position.
2. Pull up on the middle of the cable assembly.
3. With the aid of an assistant, raise the
endgate 45 degrees.
4. Remove the cable (7) on each side from the side
panel striker bolts.
5. Remove the endgate (3) from the right side hinge
assembly.
6. With the aid of an assistant, remove the left hinge
assembly.

264350

Installation Procedure
1. With the aid of an assistant, lift the endgate.
2. Install the endgate (3) to the side panel hinge
assemblies holding the gate at a 45 degree angle.

264350

3. Install the cable on each side onto the side panel

striker bolts (5).
 Endgate Replacement (U tility)
Removal Procedure
1. Open the endgate to a horizontal position.
2. Remove the torque rod. Refer to T o r q u e Rod
R e p la c e m e n t - R e a r C o m p a r t m e n t L id ,
3. Remove the electrical connector for rear window
release.
Support the endgate in a horizontal position with a
suitable support.
4. Remove the support cable bolts and the washers.
5. Remove the hinge pin clips.
5.1. Spread the clip in order to move the clip
above the recess in the pin.
5.2. As the pin is removed, the clip will ride on
the pin and fall free of the pin.
6. Remove the hinge pins from the right and the
left hinges
7. Remove the endgate from the vehicle.
Installation Procedure
1. Install the endgate to the vehicle.
Support the endgate in a horizontal position with a
sui table support.
2. Install the hinge pins into the left hinges and the
right hinges.
3. Install the hinge pin clips to the hinge pins.
N otice: Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
4. Install the support cable bolts and the washers.
Tighten
Tighten the support cable to bodv bolts to
29 N*m (21 Ib ft).
5. Install the electrical connector for rear windows
rel ease.
6. Install the torque rod. Refer to T o r q u e R o d
R e p l a c e m e n t - R e a r C o m p a r t m e n t L id .

Hinge Replacement - Door

Removal Procedure
1. Remove the door from the body. Refer to D o o r
R e p l a c e m e n t - R e a r in Body Rear End.
2. Remove the excess seaier surrounding the hinge.
3. Scribe the location of the existing hinges on
the body pillar and the door.
4. Center punch each of the weld marks on the
original hinge, so that all of the weld is removed
during the drill ing.
5. Drill a 3.0 mm (0.12 in) pilot hole through the
welds to a depth that penetrates only the
hinge base.
6. Using the small er hole as a pilot, drill a
13.0 mm (0.51 in) hole only through the
hinge base.
7. Drive a chisel between the hinge and the
door pillar.
277760
Installation Procedure
1. Install the bolt-on hinges to the pillar and the door
by completing the following steps:
1.1. Position the bolt-on service replacement
hinges within the scribe marks made on the
body hinge pillar at the time of the
removal.
1.2. Center punch each bolt hole location on the
body hinge pillar and/or on the door.
1.3. Drill a 13.0 mm (0.51 in) hinge attaching
hole in 3 steps in order to assure the proper
placement of the hinge.
2. Prepare the surface for the replacement hinges
using a file or a similar tool.
3. Coat the mating surfaces of the hinges with a
medium-bodied sealer.
Notice: Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
4. Install the nuts.
Install the hinges, the backing plate, the bolts, and
the nuts by completing the following steps:
4.1. Align the hinge, the pillar, and/or the door
with the holes in the hinge pillar and
the door.
4.2. Place the bolts through the hinge, the pillar
and/or the door, and the backing plate.
Tighten
Tighten the nuts to 35 N-m (26 Ib ft).
5. Install the door to the body. Refer to D o o r
R e p l a c e m e n t - R e a r m Body Rear End.
6. Apply sealer around the hinges.

Hinge Replacement - Endgate Window

Removal Procedure
1. Remove the endgate window supports. Refer to
W in d o w S u p p o r t R e p la c e m e n t - E n d g a te .
2. Remove the hinge pin retainers.
3. Remove the hinge pins (5).
4. Remove the endgate window assembly from the
vehicle.
5. Remove the endgate window garnish molding.
6. Remove the hinge (1) to the endgate
window assembly nuts.
7. Remove the hinge from the endgate window.

264379
 Installation Procedure
1. Install the hinge (1) to the endgate window.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Instairthe hinge to the endgate window
assembly nuts.
Tighten
Tighten' the hinge to the endgate window
assembly nuts to 23 N-m (17 Ib ft).
3. Install the endgate window garnish molding.
4. Install the endgate window assembly to the
vehicle.
5. Install the hinge pins (4).
6. Install the hinge pin retainers.
7. Install the endgate window supports. Refer to
W in d o w S u p p o r t R e p la c e m e n t - E n d g a te .

264379

Hinge Replacement - Endgate

Removal Procedure
1. Remove the endgate. Refer to E n d g a t e
R e p la c e m e n t ( U tility ) .
Mark the position of the hinge on the endgate.
2. Remove the hinge bolt (4).
3. Remove the hinge from the endgate (3).
3.1. Drill a pilot hole in the center of the weld.
3.2. Drill out the weld from the endgate side
of the hinge with a 3/8 inch drill bit

264350

Installation Procedure
1. Install the hinge to the endgate (3).
Use the marks made during removal in order to
position the endgate.
Notice: Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install the hinge bolt (4).
Tighten
Tighten the hinge to endgate bolt to
27 N-m (20 Ib ft).
3. Plug weld the hole that was drilled in the endgate.
4. MIG weld the hinge to the endgate around the
edge of the hinge.
5. Paint the hinge.
Lubricate the hinge.
6. Install the endgate to the pickup box.
264350
Torque Rod Replacement - Rear
Com partm ent Lid
Removal Procedure
1. Remove the bolt at the left end with the
endgate open.
2. Remove the rear bumper. Refer to B u m p e r
R e p l a c e m e n t - R e a r in Bumpers.
3. Remove the bolts retaining the torque rod to the
endgate.
With the gate in the closed position, the bolts are
accessible from under the vehicle.
4. Remove the torque rod and the retainers.

264364

Installation Procedure
1. Install the torque rod and the retainers to the
vehicle.
With the gate closed, place the torque rod and the
retainers onto the vehicle.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install the bolts to the torque rod retainers.
Tighten
Tighten the torque rod bracket bolts to
15 N-m (11 Ib ft).
3. Install the bolt at the left end with the
endgate open.
Tighten
Tighten the torque rod retainer bolt to
15 N-m (11 Ib ft).
4. Install the rear bumper. Refer to B u m p e r
R e p l a c e m e n t - R e a r in Bumpers.

Check Link Replacement - Rear Door

Removal Procedure
1. Apply cloth-backed tape to the door and to the
body pillar.
2. Remove the pin retainer.
3. Using a soft-faced hammer and locking pliers,
remove the hinge pin.
4. Remove the spring.
5. Remove the check assembly.

/
277852
 Installation Procedure
1. Install the check assembly.
2. Instal l the spring.
3. Using a soft-faced hammer and locking pliers,
install the hinge pin.
4. Install the new pin retainer.
5. Remove the cloth-backed tape from the door and
from the body pillar.

Access Hole Cover Replacement -

Rear Door
Removal Procedure
1. Remove the access hole cover screws.
2. Remove the access hole covers.

Installation Procedure
1. Install the access hole covers.
2. Install the access hole cover screws.

277847
Lock Rod and Outside Handle Replace -
Rear Door
Removal Procedure
1. Remove the trim panel, as necessary. Refer to
T r im P a n e l R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
2. Remove the water deflector, as necessary. Refer
to W a t e r D e f l e c t o r R e p l a c e m e n t .
3. Remove the access hole cover, as necessary.
Refer to A c c e s s H o l e C o v e r R e p l a c e m e n t -
R e a r D o o r.
4. Disconnect the lock cylinder rod from the rod clip.
5. Disconnect the outside handle rod from the
rod clip.
6. Remove the outside handle mounting bolts.
7. Remove the outside handle assembly.
8. Remove the door lock cylinder from the outside
handle housing.
277857
9. Complete the necessary procedures:
• For repair of a binding lock cylinder, refer to
B in d in g L o c k C y lin d e r s in Doors.
• For coding a new lock cylinder, refer to K e y
a n d L o c k C y l i n d e r C o d i n g in General
Information.
Installation Procedure
1. When installing a new lock cylinder, apply
GM P/N 12345120 lubricant or a similar lubricant
to the inside of the lock case and the cylinder
keyway.
2. Install the door lock cylinder to the outside handle
housing.
3. Install the handle assembly.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
4. Install the outside handle mounting bolts.
Tighten
Tighten the bolts to 4 N-m (35 Ib in).
5. Connect the outside handle rod to the rod clip.
6. Connect the lock cylinder rod to the rod clip.
7. Install the access hole cover, as necessary. Refer
to A c c e s s H o l e C o v e r R e p l a c e m e n t - R e a r D o o r .
8. Install the water deflector, as necessary. Refer to
W a te r D e fle c to r R e p la c e m e n t
9. Install the trim panel, as necessary. Refer to T r im
P a n e l R e p l a c e m e n t - R e a r D o o r (U tilit y ) .
Latch Control Handle Replacement -
Left Rear Door
Removal Procedure
1. Remove the trim panel , as necessary. Refer to
T r im P a n e l R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
2. Remove the water deflector, as necessary. Refer
to W a t e r D e f l e c t o r R e p l a c e m e n t .
3. Remove the access hole cover, as necessary.
Refer to A c c e s s H o l e C o v e r R e p l a c e m e n t -
R e a r D o o r.
4 . Disconnect the lower latch control rod (2) from the
control handle clip.
5. Disconnect the upper latch control rod (1) from
the control handle clip.

6. Remove the latch control handle nuts.

7. Remove the latch control handl e.

Installation Procedure
1. Install the latch control handle.
2. Install the latch control handle nuts.
 3. Connect1the upper latch control rod (!) to the
control handle clip.
4. Connect the lower latch control rod (2) to the
control handle clip.
5. Instal l the access hole cover, as necessary. Refer
to A c c e s s H o l e C o v e r R e p l a c e m e n t - R e a r D o o r .
6. Install the water deflector, as necessary. Refer to
W a te r D e fle c to r R e p la c e m e n t
7. Install the trim panel, as necessary. Refer to T r im
P a n e l R e p la c e m e n t - R e a r D o o r ( U tility ) .

Handle Replacement - Endgate (Pickup)

Removal Procedure
1. Lower the endgate.
2. Remove the three bolts and the washers from the
back of the endgate (1) from the back of the
endgate, behind the handl e.
3. Raise the endgate.
4. Remove the bezel from around the handle by
prying gently.
Inspect the bezel for damage to the retention
prongs. If any prongs are broken or bent, replace
the bezel.
5. Remove the latch operating rods from the
retainers on the handle by pushing the rods back.
6. Remove the handle assembly from the endgate.

Installation Procedure
1. Install the handle assembly into the endgate (1).
2. Install the latch operating rods into the retainers
on the handle.
3. Install the bezel to the handle and the endgate.
Lower the endgate.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
4. Install the three bolts and the washers into the
handle from the back of the endgate.
Tighten
Tighten the endgate to handle bolts to
25 N-m (181b ft).

264359
 Handle Replacement - Endgate (Utility)
Removal Procedure
1. Lower the endgate.
2. Remove the trim panel . Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( P ic k u p o r U t ilit y ) .
3. Remove the latch assembly cover from the
endgate.
4. Remove the two bolts and the washers from the
back of the endgate behind the handle assembly.
Raise the endgate.
5. Remove the handle assembly (2) by prying gently.
6. Remove the latch operating rods (4) from the
clips on the handle by pushing the rods back.
7. Remove the handle assembly from the endgate.

264339

Installation Procedure
1. Install the handle assembly (2) into the endgate.
2. Install the latch operating rods (4) into the
clips on the handle.
Lower the endgate.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
3. Install the two bolts and the washers onto the
handle assembly from the back of the endgate.
Tighten
Tighten the endgate to handle bolts to
4 N-m (35 Ib in).
4. Install the latch assembly cover to the endgate.
The cover must be installed with both of the
gates closed for proper alignment.
5. Install the endgate trim panel. Refer to T r im P a n e l
/ R e p l a c e m e n t - R e a r D o o r ( P i c k u p o r U t ilit y ).
264339

Linkage Replacement - Endgate

Removal Procedure
1. Remove the operating handle. Refer to H a n d l e
R e p l a c e m e n t - E n d g a t e ( U t ilit y ) .
2. Lower and support the endgate (3).
Lift the cables off the striker bolts (8).

264350
 3. Remove the three bolts holding the latch
assembl y (4) to the endgate.
4. Remove the latch assembly and the rod (5).

264359

Installation Procedure
1. Instal l the l atch assembly and the rod to the 1
endgate.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install the three bolts that hold the latch
assembly (4) to the endgate.
Tighten
Tighten the latch to endgate bolts to
30 N-m (22 Ib ft).
3. Raise the endgate.
Attach the cables to the striker bolts.
4. Install the operating handle. Refer to H a n d l e 5 4
R e p l a c e m e n t - E n d g a t e ( U t ilit y ) .

264359

Latch Replacement - Endgate

Removal Procedure
1. Open the endgate to the horizontal position.
2. Remove the endgate trim panel. Refer to H a n d l e
R e p l a c e m e n t - E n d g a t e ( U t ilit y ) .
3. Remove the latch assembly cover (1).
4. Remove the locking rod from the lock assembly.
5. Remove the screws that secure the bumper
to the endgate.
6. Remove the bumper from the endgate.
7. Remove the bolts (3) securing the latch to the
endgate.
8. Remove the latch (4) from the endgate.

264385
 Installation Procedure
1. I nstal l the latch (4) to the gate.
Notice; -Refer to F a s t e n e r N o t i c e in Cautions and
2 Notices.
2. Install the bolts securing the latch to the endgate.
Tighten
Tighten the latch to the endgate bolts to
25 N-m (18 1b ft).
3. Install the bumper to the endgate.
4. Install the screws securing the bumper to the
3 endgate.
Tighten
Tighten the bumper to the endgate screws to
3 N-m (27 Ib in).
5. Install the locking rod to the window latch.
6. Install the latch assembly cover (1).
The cover must be installed with both gates
264385
closed for the proper alignment.
7. Install the endgate trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( P i c k u p o r U tility ).

Latch Replacement - Door (Door Lower)

Removal Procedure
1. Remove the door trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
2. Remove the water deflector, as necessary. Refer
to W a t e r D e f l e c t o r R e p l a c e m e n t
3. Remove the access hole cover, as necessary.
4. Disconnect the control rod (2) from the latch.

277861
 5. Remove the control latch bolts.
Remove the spacer (2).
6. Remove the control latch from the door.

277862

Installation Procedure
1. Install the control latch to the door.
2. Install the control latch spacer (2).
Install the bolts.

3. Connect the control rod (2) to the latch.

4. Install the access hole cover, as necessary.
5. Install the water deflector, as necessary. Refer to
W a te r D e fle c to r R e p la c e m e n t.
6. Install the door trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r (U t ility ).

277861
 Latch Replacement - Door (Door Upper)
Removal Procedure
1. Remove the door trim panel . Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
2 . Remove the water deflector, as necessary. Refer
to W a t e r D e f l e c t o r R e p l a c e m e n t .
3. Remove the access hole cover, as necessary.
4. Disconnect the control rod (1) from the latch.

5. Remove the latch cover screw.

6. Remove the latch cover.

277864

7. Remove the latch bolts.

8. Remove the latch from the door.

277865
Installation Procedure
1. Install the latch to the door.
2. Install the latch bolts.

3. Connect the control rod (1) to the latch.

4. Install the access hole cover, as necessary.
5. Install the water deflector, as necessary. Refer to
W a te r D e fle c to r R e p la c e m e n t.
6. Install the door trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .

Lock Replacement - Rear Door

Removal Procedure
1. Remove the door trim panel, as necessary. Refer
to T r im P a n e l R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
2. Remove the access hole cover, as necessary.
Refer to A c c e s s H o l e C o v e r R e p l a c e m e n t -
R e a r D o o r.
3. Remove the lock rod from the lock assembly
rod clip.
4. Remove the lock assembly bolts.
5. Remove the lock assembly from the door.
 Installation Procedure
1. Install the lock assembly to the door.
2. I nstall the lock assembly bolts.
3. Instal l the lock rod to the lock assembly clip.
4. I nstall the access hole cover, as necessary. Refer
to A c c e s s H o le C o v e r R e p la c e m e n t - R e a r D o o r.

277855

Lock Actuator Replacement - Door

Removal Procedure
Tools Required
J 3 4 9 4 0 Rivet Gun
1. Remove the trim panel , as necessary. Refer to
T r im P a n e l R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
2. Remove the water defl ector, as necessary. Refer
to W a t e r D e f l e c t o r R e p l a c e m e n t .
3. Remove the access hole cover, as necessary.
Refer to Access H o l e C o v e r R e p l a c e m e n t -
R e a r D o o r.

277847

4 . Remove the actuator lock control rod (1).

5. Disconnect the actuator wiring connector.
6. Drill out the rivets.
Remove the actuator from the door.
Installation Procedure
1. Using the J 3 4 9 4 0 with rivets, install the actuator
to the door.
2. Install the actuator lock control rod (1).
3. Connect the actuator wiring connector.

277856

4. Install the water deflector, as necessary. Refer to

W a te r D e fle c to r R e p la c e m e n t.
5. Install the trim panel, as necessary. Refer to T r im
P a n e l R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
6. Install the access hole cover, as necessary. Refer
to A c c e s s H o l e C o v e r R e p l a c e m e n t - R e a r D o o r .

277847

Bumper Replacement - Rear Door

Removal Procedure
1. Remove the bumper bolts.
2. Remove the bumper assembly (1).

277862
 Installation Procedure
1. Install the bumper assembly (1).
2. Install the bumper bolts.

Lock Striker Replacement - Endgate

(Pickup)
Removal Procedure
1. Lower the endgate to a support.
Lift the cables off the striker bolts.
2. Remove the striker and the cable bolt (5).
3. Remove the striker bolt.
4. Remove the striker (1).

Installation Procedure
1. Install the striker (1) to the side panel.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install the striker bolt (6).
Tighten
Tighten the striker bolt to 30 N-m (22 Ib ft).
3. Install the striker and the cable bolt.
Tighten
Tighten the striker and the cable bolt to
30 N-m (22 Ib ft).
4. Raise the endgate.
Attach the cables to the striker bolts.

264355
Lock Striker Replacement - Endgate
(Utility Adjustment)
1. Loosen the striker bolt.
2. Move the assemblies up or down, forward or
backward, in order to obtain the proper close
of the endgate.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
3. Ensure that the endgate seals completely with the
minimum closing effort.
Tighten
Tighten the striker assemblies to 63 N-m (47 Ib ft).

Window Striker Replacement - Endgate

Removal Procedure
1. Open the endgate window.
2. Remove the striker (4) to the endgate
window pin (5).
3. Remove the striker to the endgate
window bolt (6).
4. Remove the striker from the endgate window.

Installation Procedure
1. Install the striker (4) to the endgate window.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions
and Notices.
2. Install the striker to the gate window bolt (6).
Tighten
Tighten the striker to the endgate window bolt to
10 N-m (89 Ib in).
3. Install the striker to the endgate window pin (5).
Tighten
Tighten the striker to the endgate window pin to
10 N-m (89 Ib in).

264379
 Door Striker Replacement - Left Rear
Removal Procedure
Tools Required
J 2 9 8 4 3 - 9 TORX® Bit (Bit Size T47)
The door striker bolt is a special bolt and washer
mounted on the left door opening. The bolt passes
through a hole into a threaded plate on the inside
of the door. The lock cam (arm) of the locking
mechanism in the right door engages the striker bolt.
When the lock cam snaps around the striker bolt,
the locking mechanism secures the cargo doors.
1. Remove the trim panel, as necessary. Refer to
T r im P a n e l R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
2. Remove the water deflector, as necessary. Refer
to W a t e r D e f l e c t o r R e p l a c e m e n t .
3. Remove the access hole cover, as necessary.
Refer to A c c e s s H o l e C o v e r R e p l a c e m e n t -
R e a r D o o r.
4. Mark the position of the striker bolt spacer on the
door pillar.
5. Using the J 2 9 8 4 3 - 9 , remove the striker bolt.
Installation Procedure
1. Install the striker bolt into the door pillar
retaining plate.
2. Align the striker bolt spacer with the mark made
during the removal.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
3. Hold the spacer in position.
Tighten
Using the J 2 9 8 4 3 - 9 , tighten the striker bolt to
63 N-m (46 Ib ft).
4. Install the access hole cover, as necessary. Refer
to A c c e s s H o l e C o v e r R e p l a c e m e n t - R e a r D o o r .
5. Install the water deflector, as necessary. Refer to
W a te r D e fle c to r R e p la c e m e n t.
6. Install the trim panel, as necessary. Refer to T r im
P a n e l R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
277859
Door Striker Replacement - Body
Mounted Rear
Removal Procedure
1. Mark the position of the upper striker and/or the
l ower striker.
2. Remove the striker screw.
3. Remove the striker.

Installation Procedure
1. Install the striker to the vehicle.
2. Install the striker screw.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
3. Align the striker and the screw with the mark
made during the removal.
Tighten
Tighten the screw to 8 N-m (75 Ib in).

277863

Window Support Replacement - Endgate

Removal Procedure
C a u tio n : D o n o t a tte m p t to r e m o v e o r lo o s e n g a s
s u p p o r t a s s e m b ly a t t a c h m e n t s w it h g la s s In
a n y p o s itio n o th e r th a n fu lly o p e n a s p e r s o n a l
in ju r y m a y r e s u lt.
Important: Do not intermix the original quality gas
supports with other quality supports since not all of the
supports have the same output level.
1. Remove the window defogger wires attached to
the gas supports (2), if equipped.

284384
 2. Remove the ball sockets (4) from the glass side.
• Support the rear window glass.
• Carefully pry the gas support ball socket from
the ball.
• Insert a small screwdriver between the ball
and the ball socket.
Pull the gas support from the window.
3. Remove the ball sockets (3) from the body side.
Installation Procedure
1. Install the gas support ball socket to the body (3)
and the glass (4) sides.
2. Push the ball socket onto the ball.
3. Install the rear window defogger wires to the gas
supports (2), if equipped.

Wiring Harness Replacement - Door

Removal Procedure
Caution: R efer to B attery D isconnect Caution in
Cautions and Notices.
1. Disconnect the negative battery cable.
2. Remove the trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
3. Disconnect the wiring by completing the
following steps:
3.1. Remove the wiring contact (1) screws.
3.2. Disconnect the door wiring contact
connector.
3.3. Disconnect the window defogger wiring
connectors (5).
3.4. Disconnect the power door lock actuator
connector (4).
3.5. Remove the wiring harness retainers.
4. Remove the wiring harness from the door.

277850
Installation Procedure
1. Instal l the wiring harness to the door.
2. Connect the wiring by completing the
following steps:
2.1. Install the wiring harness retainers.
2.2. Connect the power door lock actuator
connector (4).
2.3. Connect the window defogger wiring
connectors (5).
2.4. Connect the door wiring contact (1)
connector.
2.5. Install the door wiring contact screws.
3. Install the trim panel. Refer to T r im P a n e l
R e p l a c e m e n t - R e a r D o o r ( U t ilit y ) .
4 . Connect the negative battery cable.

277850
 Pickup Box Replacement
Removal Procedure
1. Remove the taillamp wiring connectors and the
ground wire under the back of the box.
2. Open the cover to the gas cap.
3. Remove the screws holding the neck of the gas
filler tube to the side panel.
4. Remove the filler neck ground strap.
5. Remove the eight bolts (2) holding the box (1) to
the frame rails (9), from under the box.
6. Remove the pickup box (8) from the vehicle.

277611
Installation Procedure
1. I nstal l the pickup box (8) to the vehicle.
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install the 8 bolts (2) holding the box (1) to the
frame rails (9), from inside the frame rails.
Tighten
Tighten the box to the frame rail bolts to
70 N-m (52 Ib ft).
3. Install the neck of the gas filler tube to the side
panel with the screws.
4. Install the filler neck ground strap.
5. Install the wiring connectors and the ground wire
to the taillamp assemblies under the back of
the box.

Fender Replacement - Stepside

Removal Procedure
1. Remove the taillamp. Refer to T a il/T u r n S i g n a l
L a m p R e p l a c e m e n t ( P ic k u p , S u b u r b a n , U t ilit y )
in Lighting Systems.
2. Remove the pads from the fender steps.
3. Remove the fender to the brace screws (3,6).
4. Remove the brace to the support bolts (1).

277604
5. Remove the fender to the support (3) bolts.
 6 . Remove the side panel screws (1,2) at the
taillamp pocket.
7. Remove the fender to the side panel screws.
8 . Remove the fender to the front panel screws.
9. Remove the fender.
10. Remove the fender supports to the side
panel bolts.

277605
 Installation Procedure
N o t ic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
1. Install the fender supports (3,5) and the screws,
to the side panel.
Tighten
Tighten the fender support screws to
18 N-m (131b ft).

277607
 2. I nstall the fender to the side panel with the
screws ( 1 ,2 ).
Tighten
Tighten the fender to the side pane l screws to
18 N-m (13 Ib ft).
3. Install the brace to the support bolts.
Tighten
Tighten the brace to the support bolts to
18 N-m (13-lb ft).
4. Install the fender to the front panel screws.
Tighten
Tighten the fender to the front panel screws to
18 N-m (131b ft).
5. Install the fender to the brace bolts.
Tighten
Tighten the stepside fender to the brace bolts to
18 N-m (131b ft).
6 . Install the side panel screws at the taillamp
pocket.
Tighten
Tighten the side panel screws to 18 N-m (13 Ib ft).

277605

7. Install the fender to the support screws.

Tighten
Tighten the fender to the support screws to
18 N-m (131b ft).
8 . Install the brace to the support screws (1).
Tighten
Tighten all the other screws to 18 N-m (13 Ib ft).
9. Install the pads to the fender steps.
10. Install the taillamp. Refer to T a il/T u rn S ig n a l L a m p
R e p la c e m e n t (P ic k u p , S u b u rb a n , U tility) in
Lighting Systems.

277604
 Fender Replacement - Rear Dual Wheel
Removal Procedure
1. Remove the wiring connector from the sidemarker.
2. Remove the fender (4) from the side panel bolts.
3. Remove the fender from the brace bolts. (6 , 7)
4. Remove the wheelhouse filler panel and the bolts.
5. Remove the nuts (1) from the fender studs.
6 . Remove the fender from the side panel.

Installation Procedure
N o t ic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
1. Install the fender (4) to the side panel with
the bolts.
Tighten
Tighten the fender to the side panel bolts to
25 N-m (181b ft).
2. Install the nuts (1) to the fender studs.
Tighten
Tighten the nuts to the fender studs to
25 N-m (18 1b ft).
3. Install the wheelhouse filler panel with the bolts.
4. Install the fender to the brace bolts (6 , 7).
Tighten
Tighten the fender to the brace bolts to
25 N-m (18 1b ft).
5. Install the wiring connector to the sidemarker.

277609
Garnish Molding Replacement - Liftgate
Removal Procedure
1. Open the endgate.
2. Remove the window molding retainers.
3. Remove the window molding.

Installation Procedure
1. Install the window molding to the endgate window.
2. Install the window molding retainers.
• Push the retainers in.
• There are five retainers for each upper
molding and three retainers for each lower
molding.
3. Close the endgate.

264373

Weatherstrip Replacement - Endgate

Removal Procedure
1. Open the endgate.
2. Remove the endgate window weatherstrip from
the roof panel.

264374
 Installation Procedure
1. Install the endgate window weatherstrip to the
roof pane l .
2. Close the endgate.

264374

Weatherstrip Replace - Rear Compartment

Opening
Removal Procedure
1. Open the door.
2 . Pull the weatherstrip from the door pinchweld
flange.

Installation Procedure
1. Install the center weatherstrip assembly.
2. Firmly push the weatherstrip to the center of the
upper roof flange.
3. While firmly pressing the weatherstrip to the
flange, peel off the backing paper.
4. Close the door.

277872
Weatherstrip Replacement - Rear Door
Removal Procedure
Tools Required
J 38778 Trim Panel Remover
1. Open the door.
2. Using the J 3 8 7 7 8 , remove the weatherstrip from
the mounting surface.

Installation Procedure
1. Install the weatherstrip to the mounting surface by
completing the following steps:
• Peel off the backing paper.
• Press the retainers into place.
2 . Close the door.
Description and Operation
Liftgate Window Release Circuit
Description
The liftgate window release circuit operates only when
the vehicle is in the PARK or NEUTRAL position in
order to deny release of the liftgate while the vehicle is
moving. The system incorporates a liftgate release
switch, liftgate release motor, and the park/neutral
position switch. Voltage to the switch is supplied
through CKT 640 (ORN) from the CIG LTR fuse. When
the liftgate release switch is depressed, voltage is
supplied through CKT 1576 (BLK) to the liftgate
release motor. Ground for the liftgate release motor
comes from the G 105 to the park/neutral position
switch through CKT 150 (BLK). If the transmission is
in the PARK or NEUTRAL position, the ground path is
opened through CKT 1737 (YEL) to the liftgate
release motor. This releases the liftgate.
On vehicles equipped with remote keyless entry, the
liftgate release switch can be bypassed by actuating
the button on the remote transmitter. This signals
the remote control door lock receiver to supply voltage
to the liftgate release motor.
Plastic Panel Information and Repair
Specifications
Repair Materials - Flexible Plastic Part
R ecom m ended Repair
Therm oset Plastic Type Type o f Repair Material Availability
GM Goodwrench Compoxy
Repair Material (GM GM Dealer/ Retailer
Most flexible and semi P/N 12377980* or equivalent)
Most repairs*
flexible plastic* CMR-8 Composite Repair
Material, P/N 82091 or Refer to local paint supplier
equivalent
* TPO, TEO, (Polyolefin Plastics) require the application of GM P/N 1052364 polyolefin adhesive primer before the GM
P/N 12377980 repair compound is applied.

Repair Materials - Rigid Plastic Part

R ecom m ended Repair
Therm oset Plastic Type Type o f Repair Material Availability
GM Goodwrench Structural
Bonding Epoxy (GM GM Dealer/Retailer
P/N 12345726 or equivalent)
Most rigid plastic parts Cosmetic filling
Sikkens Polystop LP or
equivalent polyester Refer to a local paint supplier
repair putty
GM Goodwrench Structural
Bonding Epoxy (GM GM Dealer/Retailer
Cosmetic repair; Adhesive P/N 12345726 or equivalent)
Most rigid plastic parts
bonding
Lord Fusor SMC Body Panel
Refer to local paint supplier
Repair Adhesive or equivalent
GM Goodwrench Structural
Bonding Epoxy (GM GM Dealer/Retailer
P/N 12345726 or equivalent)
Most rigid plastic parts Adhesive bonding
Dynatron Dyna-Weld Plio Grip
or equival ent (OE structural Refer to local paint supplier
adhesive)
GM Goodwrench Structural
Most rigid plastic parts Adhesive structural* bonding Bonding Epoxy (GM GM Dealer/Retailer
P/N 12345726 or equivalent)
US Chemical and Plastic
System 2000 Structural Refer to local paint supplier
Adhesive bonding Adhesive
Most rigid plastic parts or US Chemicals customer
Structural bonding P/N 82007B = 30 min service 1 800 321 0672
P/N 82014B = 9 min
* Structural adhesive bonding may require the use of a pneumatic applicator, A8-37479-1A, Kent-Moore
or equi val ent, to speed the application of the GM 12345726 epoxy. 1~800-GM~TOOLS
Repair Instructions
Plastic Panels 5. Determine whether the adhesive is applied to the
vehicle or the replacement panel.
Repair Procedure 6 . Apply a consistent adhesive bond to the prepared
Important: Follow these guidelines when performing surfaces.
SMC repairs: 7. Mechanically retain the panel in place in order to
• Clean, scuff, and solvent wipe all the areas to be wet out the adhesive a long the entire bonding
repaired. surface.
• For added strength and durability, V-groove and 8 . Allow the area to cure according to the adhesive
reinforce at least one side of SMC joints using manufacturer’s recommendations.
a tacky mesh tape or equivalent.
• When partial panel replacement is performed, use General Plastic Repair Instructions
2 inch backing patches made from SM C or The following procedures should be followed when
E-coated steel, as a reinforcement for all the butt repairing all types of thermoset plastic:
joints.
1. Use the supplies and the repair materials from the
1 . Scuff the area where repair is to be performed. same manufacturer. Do not intermix systems.
2. Clean the bond area with a lint-free rag using Mixing materials from different manufacturers can
a water-based cleaner. produce unsatisfactory results.
3. Cracks in SMC should be grooved and reinforced 2 . Clean the inner and outer surfaces of the repair
on at least 1 side using a tacky mesh tape or area with a soap impregnated scouring pad in
equivalent order to remove any dirt or mold release agent. A
4. Sectioning joints require backing strips 50 mm mold release agent is used during manufacturing
(2 in) wide, which can be cut from leftover in order to prevent the part from sticking to
pieces of SMC. the mold. This release agent may be present in
large enough concentrations to affect adhesion.
5. Apply a thin coat of Goodwrench Structural
Bonding Epoxy GM P/N 12345726, or equivalent, 3. After washing, clean the area a second time with
to the entire joint area extending across the cut a wax and grease remover. Use only enough of
lines and across the backing strip. the remover to dampen a cloth. Too much of
the solvent will saturate the panel and may
• Use tacky mesh tape or an equivalent migrate put later, affecting the finish. Use a tack
reinforcement matting. rag and air for finish cleanup. Allow the panel
• Allow to cure according to the adhesive to dry thoroughly.
manufacturer’s recommendations. 4. Apply force around the damaged area in order to
6 . Shape and refinish the repair areas as necessary look for hidden damage such as hairline cracks.
to resemble the original appearance. Small cracks and faults in the bonds and the
panels will eventually grow larger if left
Bonding Procedure unattended. Drill a 3 mm (1/8 in) hole at each end
Important: Use the following procedure when bonding of a crack in order to prevent any further
undamaged SMC to epoxy-coated steel. cracking.
1. Prime all the bare metal areas with an 5. Remove the surface finish from the area to be
anti-corrosion material. Refer to GM 4901 Refinish repaired. Adhesives are designed to adhere to
Manual for approved materials the plastic substrate, not the finish.
• Some paint manufacturers recommend a 6 . Prime a metal surface before applying the repair
pre-primer when bonding to epoxy. material.
• Always refer to the paint manufacturer’s 7. Repair the inner surface of the panel first.
recommendations. 8 . When using a mat reinforcement to repair the
• Do not combine paint systems. inner or outer surface of a panel, inspect that
2 . Clean the bond area with a lint-free rag using a there are no strands of the mat left uncovered or
water-based c leaner. unsaturated with the repair material. If exposed,
the mat may act as a wick and draw moisture into
3. Scuff both surfaces to be bonded using a scuff the repair area, affecting the integrity and the
pad such as 3M ’s Scotch-Brite Red scuff pad finish.
P/N 07447 or equivalent.
Inspect the rear of the damaged panel for tool
4. Ensure that the surface is c lean and dry before clearance. If accessing the repair with a
applying the adhesive. saturation roller, a grinder, or a sander is
• Use compressed air. impossible, do the repairs by hand.
• Do not wipe the surface with a hand or a rag.
10. Align the damaged or spliced area with a brace
and clamps if the damage is severe. For a
smaller repair, use a heavy tape on the outer
surface in order to maintain the alignment until the
inner repair material has cured.
11. If welding is necessary, do not allow the flame or
the welding heat to come into direct contact with
the plastic body panels. Protect the surrounding
area with a fire retardant fabric. Several layers of
aluminum foil make an excellent heat shield if
not in direct contact with the flame.
12. Inspect the rear side of the work area before
making repairs in order to avoid possible
damage to wires, motors, etc.
13. Fiberglass parts will not yield or take a set as with
steel parts, thus they cannot be straightened. If
poor alignments are suspected, due to a collision
or other damage inspect the steel reinforcements
for damage and replace or repair them before
repairing the plastic parts
14. Save any useful size pieces of repair material
when cleaning up the work area. These pieces
can be used for reinforcing smaller repair areas.
15. Force dry Structural Bonding Epoxy with heat.
Heat speeds the cure time and increases th&
bond strength. Follow the manufacturer’s curing
recommendations.

Gouge or Puncture Repair

When the fiberglass laminate is not pierced through or
the damage extensive, the damaged area can be
repaired using the following procedure:
1. Clean and inspect the damaged area. Refer to
General Plastic Repair Instructions.
2. Finish the cleanup using a tack rag and air.

95551
__ — — i 3 , Sand the damaged area down to the fiberglass
laminate.
Use a sander with a vacuum attachment in order
to minimize dust.

4. Grind or file the edges of the damaged area in

order to form a dish.
The side of the dish should have a pitch for a
maximum bonding surface.

5. Scuff sand the area surrounding the damaged

area in order to provide a good bonding surface.

95514
6 . Clean the repair area again using a water based
wax and grease remover.
7. Finish the c leanup using a tack rag and air.

95551

8 . Mix the recommended repair material. Refer to

R e p a ir M a te ria ls - F le x ib le P la s tic P a r t or R e p a ir
M a te ria ls - R ig id P la s tic P a rt.
9, Apply the repair material to the damaged area
until the repair is slightly higher than the
surrounding area.

95515

10. Cure the repair material. Follow the manufacturer’s f — —- —

recommendations.

193342
 1 1 . Rough out the surface using a #80 grit disc on a
D A sander or a curved-tooth body file.

12 . Apply a polyester type material, to provide a

uniform surface for sanding, such as Silkens
Polystop LP, or equivalent.

95562

13. Finish sand with a dual action random orbital

sander.
14. Prime and refinish as necessary. Refer to
GM 4901 M-D for a listing of approved materials.
Follow the procedures recommended by the
material manufacture.
Panel Replacement - Partial
When you splice a replacement panel or a portion of a
replacement panel to an existing panel, use the
fo llowing procedure:
1. Clean and inspect the damaged area. Refer to
G e n e r a l P la s tic R e p a ir In s tru c tio n s .

95551

2 . Cut the damaged area and/or the replacement

panel to the appropriate size so that the panel fills
the opening.

95553

3. Scuff sand the damaged area and the replacement

panel’s mating surfaces.

95556
 4. Fit the panel to the opening:
• If the bonding strips are exposed, mechanically
attach ( 1) and bond the strips together.
• If the bonding strips are not exposed, cut or
grind the edge of the panels in order to
form a good butt joint (3). Then bevel the
edges (2) to about 30 degrees in order to form
a dished butt joint.

95567

5. Install a backing patch (3). Refer to B a c k in g P a tc h

F a b ric a tio n .

6 . Mix and apply, follow the manufacture’s

instructions, a light coat of the repair material to
the outside of the damaged area.
7. Lay a piece of reinforcement mat into the repair
material.
• The mat should extend 38-51 mm (1.5-2.0 in)
beyond either side of the repair area.
• All of the mat must be at a level below the
final finished surface.
8. Using an applicator, saturate and remove any
trapped air from the repair area.

9. Apply a second coat of the repair material in the

same manner.

10. Lay a second piece of mat into the repair area in

the same manner.

95561
11. Apply the final layer or repair material in the same
manner until the repair material ( 1) is at a level
s lightly higher than the surrounding area.

12. Cure the material according to the manufacturer’s

instructions.
13. Apply and cure additional layers as needed.

14. Rough out the surface using a #80 grit disc on a

D A sander.
15. Apply a polyester type material to provide a
uniform surface for sanding, such as Silkens
Polystop LP, or equivalent.
16. Prime and refinish as necessary. Refer to
GM 4901 M-D for a listing of approved materials.
Follow the procedures recommended by the
material manufacture.

95546

Panel Replacement - Complete

Removal Procedure
Im portant: W ear safety equipment when you work
with plastic.
1 . Cut a large window in the panel to be replaced to
gain access to the bond adhesive.
• Cut only deep enough to cut through the panel
being replaced.
• Most SMC plastic panels are
3 mm (0.125 in) thick.
2 . Use a heat gun to soften the bonding adhesive.
Heat to 400 degrees.
3. Cut through the adhesive bond with a putty knife.
4. Remove the damaged panel.

Installation Procedure
1 . Use a scraper in order lo remove all the old
adhesive.
2 . Wash the bonding surfaces with soap and water.
DO NOT use a solvent.
3. Install the proper bonding material to the bond
surface. Refer to Repair M a te ria ls - R ig id P la s tic
Part or Repair Materials - Flexible Plastic Part
Large panels require a pneumatic applicator
to speed the application of the fast curing
adhesive.
4. Position the panel.
5. Clamp the panel with vise grips, or equivalent.
6 . Cure the repair. Follow the repair material
manufacture’s recommendations.
B acking Patch F abrication
Before proceeding, refer to General Plastic Repair
Instructions and Plastic Repair Precautions.
The following are three methods of fabricating a
backing patch:
• Method 1: Fabricating a patch directly on the back
of the damaged area. Layers of repair material
and glass cloth mat are applied one at a time to a
clean and sanded surface.
• Method 2: Cutting a patch from a scrap piece of a
replaced panel.
• Method 3: Fabricating a patch on the outside of
the damaged area to be reapplied to the inside
of the damaged area.
Any method can be used, but one method may be
easier than another depending on the given situation.
Read over each of the following methods in order
to decide which will work best in a given situation.

Method 1
1. Cut a piece of the reinforcement mat, to the
desired shape, so that the mat overlaps all
sides of the back of the damage area by
38-51 mm (1.5-2.0 in).

2. Determine the proper repair material. Refer to

Repair Materials - Flexible Plastic Part or Repair
Materials - Rigid Plastic Part.
3. Mix the repair material according to the
manufacturer’s instructions.
4. Apply, follow the manufacturer’s instructions, a
skim coat of the repair material to the back of
the damaged area.
5. Lay the pre-cut piece of reinforcement mat into
the skim coat of the repair material,
• Use the applicator in order to press the mat
until saturated.
• Inspect for exposed fibers or trapped air.

6 . Apply additional skim coats as needed to

strengthen.

7. Allow the material to cure according to the

manufacturer’s instructions.
8 . Allow the repair area to return to room
temperature.
95553

2 . Sand and clean the surface of the patch in order

to remove any paint or finish material which could
prevent proper bonding.
3. Determine the proper repair material. Refer to
R e p a ir M a te ria ls - F le x ib le P la s tic P a r t or R e p a ir
M a te r ia ls - R ig id P la s tic P a rt.
4. Mix the repair material according to the
manufacturer’s instructions.

5. App ly, follow the manufacturer’s instructions, a

skim coat of repair material to the back of the
damaged area.
6 . Install the patch:
6.1. Align the patch over the damage on the
back of the panel.
6.2. Clamp or prop the patch onto the panel.
6.3. Cover with repair material any voids or gaps
a the edges of the patch that could allow
entry of water or chemicals.
7. Cure according to the manufacturer’s instructions.
8 . Remove the clamp or the prop when curing is
complete.

193342

Method 3
1 . Gut a piece of wax paper or polyethylene film
material such as that used to wrap food:
1.1. Cut the material to extend about 75 mm
(3 in) beyond the repair area.
1 .2 . Tape the material to the outside of the
repair surface.

95548

2 . Cut a piece of the glass cloth mat to the desired

shape, extending the mat 38-51 mm (1 .5 -2.0 in)
beyond the repair area.

95559
 3. Determine the proper repair material. Refer to
R e p a ir M a te ria ls - F le x ib le P la s tic P a r t or R e p a ir
M a te ria ls - R ig id P la s tic P a rt.
4. Mix the repair material according to the
manufacturer’s instructions.
5. Apply, follow the manufacturer’s instructions, a
layer of the repair material.

95562

6 . Place a layer of the mat over the repair material.

7. Smooth out any wrinkles in the mat. Follow the
contour of the panel.

95561

8 . Apply a coat of repair material.

 9. Cover the repair material with the wax paper or
polyethylene.
10. Press against the wax paper with a saturation
roller or squeegee in order to ensure saturation
of the mat and to remove any air bubbles.
11. Continue applying layers as before as needed to
strengthen.
12. Form the patch to match as close as possible the
surface of the panel.

13. Cure according to manufacturer’s instructions.

14. Allow to return to room temperature.
15. Pop off the patch.

16. Remove the wax paper or polyethylene.

 17. Apply a skim coat of repair material.
18. Install the patch:
• Align the patch over the damage on the back
of the panel.
• Clamp or prop the patch onto the panel.
• Cover with repair material any voids or gaps at
the edges of the patch that could allow entry
of water or chemicals.

95562

19. Cure according to the manufacturer’s instructions.

20. Remove the clamp or the prop when curing is
complete.

Plastic Structure Repair

Before proceeding, refer to General Plastic Repair
Instructions and Plastic Repair Precautions.
1. Clean and inspect the damaged area. Refer to
General Plastic Repair Instructions.

95517
2. Clamp or tape the damaged area in order to
maintain alignment.
3. Prepare the damaged area for the installation
of a backing patch. If the rear of the damage is
accessible proceed with steps 4 through 6 .
If the rear of the damage is not accessible skip
to step 7.

4. Scuff the inner surface with a #80 grit disc on a

D A sander or by hand if the access is limited.

95521

5. Determine the proper repair material. Refer to

R e p a ir M a te ria ls - F le x ib le P la s tic P a r t or R e p a ir
M a te ria ls - R ig id P la s tic P a rt.
6 . Mix the repair material following the
manufacturer’s instructions.
7. Apply, follow the manufacturer’s instructions, the
repair material to the inner surface.
 8. Apply a backing patch and skip to step 21. Refer
to Backing Patch Fabrication.

95527

9. If the rear of the damaged area is not accessible

remove some of the damaged material in order to
form an access hole through which you can
slip a backing patch.
10. Cut a backing patch from a scrap piece of panel.
Refer to Backing Patch Fabrication.
11. Sand the mating surface of the patch.
12. Reach through the access hole and sand the
underside of the repair area.

95531

13. Drill 2 holes in the backing patch.

14. Thread a piece of waxed wire through the holes in
order to assist in holding the patch in place after
installation.
15. Determine the proper repair material. Refer to
Repair Materials - Flexible Plastic Part or Repair
Materials - Rigid Plastic Part.
16. Mix, follow the manufacturer’s recommendations,
the correct repair material.
17. Apply, follow the manufacturer’s recommendation,
the correct repair material to the mating surface of
the patch.
18. Slip the patch through the access hole.
19. Pull up hard on the waxed wire until the repair
material squeezes out on all sides.

20. Twist the wire around a piece of wood in order to

hold the patch in position until the repair
material cures.

21. Cure the repair material according to the

manufacturer’s instructions.
 22. Remove any tape, clamps, or waxed wire used to
maintain alignment.

95519

23. On the outer surface of the panel, bevel the

damaged area with a #50 grit Roloc disc in order
to extend the contact between the repair
material and the substrate.

24. Using a D A sander, feather out several inches

beyond the damaged area in order to remove any
paint or primer from the substrate, and provide
a proper adhesion surface.
• Use a #80 grit disc on rigid panels.
• Use a #180 grit disc on flexible panels.
25. Carefully and smoothly app ly a light coat of repair
materia l to the damaged area.

95515

26. Add mat material as needed to strengthen. I “

27. Apply a final layer of repair material (1) at a
slightly higher level than the surrounding area.

366225

28. Cure the repair material according to the I

manufacturer’s instructions.

193342
- I 29. Rough out the surface using a #80 grit disc on a
D A sander or a curved-tooth body file.

30. Finish sanding using a #220-320 grit wet or dry

sandpaper on a sanding block.
31. Prime and refinish as necessary. Refer to
GM 4901 M-D for a listing of approved materials.
Follow the procedures recommended by the
material manufacturer.
Description and Operation
How to Identify Plastic Parts No Code Found
Important: Do not use a plastic burn test in order to
distinguish the types of plastics. The burn test
¥___ produces vapors that are harmful to you.

SAE
13

o
3
---- mm Perform one or both of the following tests to determine

<
if the part is thermoplastic (polyolefin) or thermoset
T (non-polyolefin).

Float Test
SAE J 1. Cut a shaving of plastic from the back of the part.

SMC 3 mm The shaving should be free of mold release

agents and paint.
i 2 . Place the shaving in a container of water.
i • Thermoplastic (polyolefin) floats.
• Thermoset (non-polyolefin) sinks.

(T T O > 3 mm Abrasion Test

• Sand a spot near the damaged with Grade 36
♦ Roloc Disc.
95570 • Thermoplastic (polyolefin) material melts or frays
Plastic parts can be identified by the SAE the code, when sanded.
which is usually found on the rear of the part, and/or by • Thermoset (non-polyolefin) material sands cleanly.
the characteristics of the plastic. Knowing the type Thermoplastic and thermoset plastics can be either
of plastic aids in selecting the proper repair materials rigid or flexible. Thermoplastic plastic parts are
and in selecting the proper repair procedure. best repaired with a hot iron plastic material-feed
Look for the SAE code stamped into the part. welder, but are usually replaced. Thermoset plastic can
be repaired with epoxy or other more rigid two
Code Found package repair material.
1. Match the code to those in the plastic identification
• For rigid thermoset repair materials refer to Repair
chart to determine whether the plastic is
Materials - Rigid Plastic Part.
thermoplastic or thermoset plastic, and whether
the plastic is rigid or flexible. Refer to P la s tic • For flexible thermoset repair materials refer to
Id e n tific a tio n a n d R e fin is h in g S y s te m s . Repair Materials - Flexible Plastic Part.
2 . Identify any special handling procedures. Refer to • For general repair instructions refer to General
H a n d lin g P re c a u tio n s F o r P la s tic . Plastic Repair Instructions.

Plastic Identification and Refinishing Systems

Chem ical Examples of
Identifying Sym bol - Com position or Typical Area(s) Where Common/Trade
Old Sym bol in ( )’s Plastic Family Nam e Part is Used Names Type of Plastic
Armrest Support,
ABS, Absafil, Abson,
Acrylonitrile/ Console, IPC, Steering
ABS Cycolac, Dyel, Thermoplastic
Butadiene- Styrene Column Bracket/Jacket,
Kralastic, Lustran
Trim Molding
Acrylonitrile/
Baybland, Cycoloy,
ABS + PC Butadiene- Styrene + l/P, IPC Rigid
KHA, Proloy
Polycarbonate
Head Rest Cover, l/P
ABS/PVC ABS/Vinyl (Soft) Pad, Trim ABS Vinyl Flexible, Vinyl
Molding/Panel
Ethylene Propylene Body Panel, Bumper
EPDM EPDM, Nordel Rigid
Diene Monomer Impact Strip
Head Rest Cover, Misc
EVA (EVAC) Ethylene/Vinyl Acetate Elvax, Microthane Flexible
Soft Trim
Headlamp Bezels,
Nylon, Capron, Zytel,
Quarter Panel
PA Pol yamide Rilsan, minion, Vydyne, Rigid
Extensions, Exteri or
Welland
lish Trim Panels
 Plastic Identification and Refinishing Systems (cont’d)
Chemical Examples of
Identifying Symbol - Composition or Typical Area(s) Where Common/Trade
Old Symbol in ( )’s Plastic Family Name Part is Used Names . Type of Plastic
Exterior Finish Trim
Capron, Minion, Nylon,
Panel , Headlamp
PA, PAG, PAGG Polyamide Rilsan, Vydyne, Rigid, Thermoset
Bezel, Quarter Panel
Wellamid, Zytel
Extension
Polymide +
PA + PPE Exterior Trim, Fender GTX Rigid, Thermoset
Polypheneylene Ether
Polybutylene,
PBT + TEEE Terephthalate + Ether, Fascia, Rocker Panel
Bexloy "M" Rigid
(PBTP+ EEBG) Ester Block Molding
Compound
Interior Rigid/Hard Trim
PC Polycarbonate Calibre, Lexan, Merlon Rigid, Thermoset
Panel, Valance Panel
Polycarbonate +
Macroblend,
PC + PETP Polybutylene, Bumper Fascia Flexible, Thermoset
Valox, Xenoy
Terephthalate
Fuel Tank Shield, Inner Alathon, Dylan,
Fender Panel, Interior Foriflex, Hi-fax,
PE Polyethylene Rigid, Thermoplastic
Trim Panel, Seat Belt Hosalen,
Cover, Spoil er, Valance Marlex, Paxon
Amberol, Bakelite,
PF Phenol1 Formaldehyde Ashtray Durez, Genal, Phenolic, Rigid, Thermoset
Plyophen, Resinox
Bumper Fascia, Cowl
Panel, Deflector Panel,
Azdel, Daplen,
Door Panel, Inner
PP Polypropylene Fender, Interior
Eseorene, Marlex,
Flexible, Thermoplastic
Novolen, Oleflo, Profax,
Molding, Kick Panel,
Tenite
Load Floor, Radiator
Shroud, Wheel Cover
Bezels, Chromed
PPE (PPO) Polyphenylene Ether Plastic, Headlamp Noryl, Oleflo, Prevex Rigid, Thermoset
Door, Ornaments
Durathon, Dylan,
Dash Panel,
PS Polystyrene Lustrex, Polystyrol, Flexible, Soft
Door Panel
Styron
Polyurethane, Bumper Fascia, Filler
Bayflex, Castethane,
PUR Thermoset Panel, Front/Rear Thermoset
RIM,RRIM
(Unsaturated) Body Panel
Geon, Pliovic,
Polyvinyl Interior Soft Trim, I/P
PVC Unichem, Vinoflex, Flexible, Vinyl
Chloride (Vi nyl) Skins, Roof Cover
"Vinyl," Vinylite
Center Console, Glove
SAN (SA) Styrene- Aery Ion itrite Box Door, Interior Foracryl, Lustran, Tyril Rigid
Trim Panel
Ethylene/ Propylene Air Dam, Bumper ' EPI, EPII, TPO, TPR
TEO (EP, EPM, TPO) Flexible, Thermoplastic
(Rubber) Fascia, Valance Panel (Thermoplastic Rubber)
TPO Thermal Plastic oletin Bumper Covers TPO Flexible Thermoplastic
Bumper Fascia, Gravel
Polyurethane, Estane, Pellethane,
TPU (TPUR) Deflector, Soft Filler Flexible, Thermoplastic
Polyolefin Roylar, Toxin
Panel, Window Molding
Air Scoop, Air Spoiler,
Fascia Extension,
Hood, Instrument
"Fiberglass,"
UP Polyester/ Thermoset
Housing, Rear
Premi-glas, Selectron, Rigid, Thermoset
SMC, Vibrinmat
Compartment Lid,
Roof, Ventilation Grid
For symbols not listed in this table, contact the Society of Automotive Engineers, 400 Commonwealth Drive
Warrendale, PA 15096-0001
 Handling Precautions For Plastic
R esistance to
Heat Resisting G asoline and
Abbreviation Material Nam e Tem perature C (F) Solvents Other C autions :
Acrylonitrile acrylic Avoid gasoline and
AAS 95 (203) Avoid brake fluid
rubber styrene solvents
Acrylonitrile Avoid gasoline and
ABS 90 (194) Avoid brake fluid
butadiene-styrene resin solvents
Acrylonitrile ethylene Avoid gasoline and
AES 90 (194) Avoid brake fluid
styrene solvents
Fiber reinforced Gasoline and most
FRP 170 (338) —
plastics solvents are harmless
Gasoline and most Avoid immersing
PA, PAG, PAGG Polyamide (nylon) 150 (302)
solvents are harmless in water
Polybutylene Gasoline and most
PBT 140 (284) —
terephthalate solvents are harmless
Avoid gasoline and
PC Polycarbonate 120 (248) —
solvents
Gasoline and most
PE Polyethylene 80 (176) Flammable
solvents are harmless
Polymethyl Avoid gasoline and
PMMA 90(194) Avoid brake fluid
methacrylate solvents
Gasoline and most
POM Polyacetal 120 (248) Avoid battery acid
solvents are harmless
Gasoli ne and most
PP Polypropylene 9 0 (1 9 4 ) Flammable
solvents are harmless
Polypropylene Gasoline and most
PPC 115 (239) Flammable
composite solvents are harmless
Avoid gasoline and
PPE Polyphenylene ether 110 (230) —
solvents
Gasoline and most
PUR Polyurethane 90 (194) Avoid brake fluid
solvents are harmless
Gasoline and most
PVC Polyvinyl chloride 90 (194) solvents are harmless Toxic when burned
if wiped up quickly
Thermoplastic Avoid gasoline and
TPE 80 (176) —
elastomer solvents
Avoid gasoline and
TPR Thermoplastic rubber 80 (176) —
solvents

Plastic Repair Precautions 6. Use a sander with a vacuum attachment whenever

possible in order to control any dust.
Adhere to the fo llowing precautions during thermoset
Wash skin with cold water in order to alleviate
plastic repair: '
minor skin irritation from glass and resin dust.
1. Apply protective cream to any exposed skin in g
Do not get any of the repair material on clothing.
order to prevent skin irritation. '
Use repair materials in a well-ventilated area.
2. Wear rubber gloves. The repair materials may produce toxic fumes.
3. Wear safety glasses when using compressed air 10. Follow the repair material manufacturer’s
and when sanding. instructions.
4. Immediately remove any mixture that comes into 11. Close all containers after use. Dirt or moisture
contact with skin. The mixture hardens quickly. contamination of the repair material can result
in an unsatisfactory repair.
5. Wear an air supplied respirator or dust mask
when grinding or sanding.
Paint/Coatings
Specifications
Clearcoat Repair Specificaiions - 3M Product
Paint Com pounding Rotary Polisher
Dual Action Orbital Hand G lazing/
Condition W et Sanding Polisher Polishing

• Perfect-lt
Polishing Pad
Glaze
P/N 05995/05996
New vehicle Premium
prep or fine — — — • Perfect-lt Foam Liquid/Paste Waxes
wheel marks Polishing Pad P/N 0654/06055
P/N 05776
• Hookit DA 6 inch
Backup Pad
P/N 05776
• Perfect-lt
* Perfect-lt
Polishing Pad
Polishing Pad • Perfect-lt Hand
Glaze
Glaze Glaze
P/N 05995/05996
Swirl marks, P/N 05995/05996 P/N 05997
water spotting, • Perfect-lt Foam
— — • Perfect-lt Foam or
or light Polishing Pad
Polishing Pad ® Premium
oxidation P/N 05776
P/N 05725/35 Liquid/Paste
• Hookit
•' Hookit DA 6 inch Waxes
SBS/Perfect-l t
Backup Pad P/N 0654/06055
Backup Pad
P/N 05776
P/N 05717/18
• Perfect-lt
• Perfect-lt
Polishing Pad
•Perfect-lt 11 Glaze
Polishing Pad
•Perfect-lt Hand
Rubbing Glaze
P/N 05995/05996 Glaze
Compound Pad P/N 05995/05996
Overspray or • Perfect-lt Foam P/N 05997
P/N 059723 • Perfect-lt Foam
medium —

®Perfect-lt 11
Polishing Pad
Polishing Pad ®Premium
oxidation P/N 05776 Liquid/Paste
Foam P/N 05776
Compound Pad • Hookit • Hookit DA 6 inch
Waxes
SBS/Perfect-lt P/N 0654/06055
P/N 05723/31 Backup Pad
Backup Pad
P/N 05776
P/N 05717/18
• Perfect-lt
Polishing Pad
• Perfect-lt
• Perfect-l t 11 Glaze
Polishing Pad
° Perfect-lt Hand
Rubbing Glaze
P/N 05995/05996 Glaze
Heavy Compound Pad P/N 05995/05996
• Perfect-lt Foam P/N 05997
oxidation or Micro P/N 059723 • Perfect-lt Foam
minor acid rain Fine 2000 • Perfect-lt 11
Polishing Pad
Polishing Pad • Premium
pitting P/N 05776 Liquid/Paste
Foam P/N 05776
• Hookit Waxes
Compound Pad
SBS/Perfect-lt
• Hookit DA 6 inch P/N 0654/06055
P/N 05723/31 Backup Pad
Backup Pad
P/N 05776
P/N 05717/18
 Clearcoat Repair Specifications - 3M Products (cont’d)
Pair Com pounding Rotary Polisher
Dual Action Orbital Hand G lazing/
Condition W et Sanding Polisher • Polishing
• Perfect-lt
• Perfect-lt
Polishing Pad
• Perfect-lt 11 Polishing Pad
Glaze ; • Perfect-l t Hand
Rubbing Glaze
Dust nibs, P/N 05995/05996 : -Glaze
Compound Pad P/N 05995/05996
minor • Perfect-lt Foam P/N 05997
Micro Fine P/N 059723 • Perfect-lt Foam
scratches, or Polishing Pad • Premium
1500 or 2000 • Perfect-lt 11 Polishing Pad
major acid rain P/N 05776 Liquid/Paste
pitting Foam P/N 05776
• Hookit Waxes
Compound Pad • Hookit DA 6 inch
SBS/Perfect-lt P/N 0654/06055
P/N 05723/31 Backup Pad
Backup Pad
P/N 05776
P/N 05717/18
• Perfect-lt
• Perfect-lt
Polishing Pad
• Perfect-lt 11 Polishing Pad • Perfect-lt Hand
Glaze
Rubbing : Glaze Glaze
P/N 05995/05996
Compound Pad P/N 05995/05996 P/N 05997
Orange peel, • Perfect-lt Foam
Micro fine P/N 059723 • Perfect-lt Foam or
paint runs Polishing Pad
1200 or 1500 • Perfect-lt 11 Polishing Pad • Premium
or sags P/N 05776
Foam P/N 05776 Liquid/Paste
Compound Pad • Hookit
• Hookit DA 6 inch Waxes
P/N 05723/31 SBS/Perfect-lt
Backup Pad P/N 0654/06055
Backup Pad
P/N 05776
P/N 05717/18

Clearcoat Repair Specifications - Meguiar Products

Paint Condition W et Sanding Cleaning Polishing
New car prep or fine Swirl Free Polish (M-82)
—■ W-6000 Pad for DA polishers
wheel marks
Swirl marks, chemical Swirl Free Polish (M-83)
— — W-9000 Finishing Pad
spotting or light oxidation
Overspray or medium Heavy-Cut Cleaner (M-85) Swirl Remover (M-82)
— W-7000 Cutting Pad W-9000 Finishing Pad
oxidation
Heavy oxidation or minor acid Compound Power Cleaner Swirl Free Polish (M-82)
rain pitting
.— . (M-84) W-4000 Cutting Pad W-6000 Finishing Pad
2000 Grade Unigrit Compound Power Cleaner Swirl Free Polish (M-2)
Dust nibs
Sanding Block (M-84) W-7000 Cutting Pad W-9000 Finishing Pad
Minor scratches or acid rain 2000 Grade Unigrit Compound Power Cleaner Swirl Free Polish (M-2)
pitting Sanding Paper (M-84) W-7000 Cutting Pad W-9000 Finishing Pad
1500 Grade Unigrit Compound Power Cleaner Swirl Free Polish (M-2)
Major runs or sags
Sanding Block (M-84) W-7000 Cutting Pad W-6000 Pad for DA Polishers
Major orange peel or acid 1500 Grade Unigrit Compound Power Cleaner Swirl Free Polish (M-2)
rain pitting Sanding Paper (M-84) W-7000 Cutting Pad W-6000 Pad for DA Polishers
Quick Detailer (M-6601) will
provide protection without
streaking. Contains the
Need for protection — —
mildest of cleaners which will
insure even application of
polish.
Introduction
Basecoat/Clearcoat Paint Systems A n ti-C o rro sio n Treatment and R epair
C a u t io n : E x p o s u r e to is o c y a n a t e s d u r in g p a i n t C a u t io n : W h e n a p p l y in g s o u n d d e a d e n e r s , o r
p r e p a r a t io n a n d a p p lic a t io n p r o c e s s e s c a n c a u s e a n t i- c o r r o s io n m a t e r ia is d u e c a r e a n d p r e v e n t a t i v e
s e v e r e b r e a t h in g p r o b le m s . R e a d a n d f o llo w a l l m e a s u r e s m u s t b e e x e r c is e d to p r e v e n t a n y
o f th e in s t r u c t io n s f r o m t h e m a n u f a c t u r e r s o f m a t e r ia l f r o m b e in g s p r a y e d in t o d o o r a n d q u a r t e r
p a i n t i n g m a t e r ia ls , e q u ip m e n t , a n d p r o t e c t i v e g e a r . p a n e l m e c h a n is m s s u c h a s d o o r lo c k s , w in d o w
r u n c h a n n e ls , w in d o w r e g u la t o r s a n d s e a t
C a u t io n : A p p r o v e d s a f e t y g la s s e s a n d g lo v e s
b e l t r e t r a c t o r s , a s w e ll a s a n y m o v in g o r r o t a t in g
s h o u l d b e w o r n w h e n p e r f o r m i n g t h is p r o c e d u r e
m e c h a n i c a l o r s u s p e n s io n p a r t s o n t h e u n d e r b o d y ,
to r e d u c e t h e c h a n c e o f p e r s o n a l in ju r y .
p a r t i c u l a r l y t h e p a r k in g b r a k e c a b le . A f t e r m a t e r i a l
All paint finish repairs of rigid exterior surfaces must a p p lic a t io n , b e s u r e t h a t a l l b o d y d r a in h o le s
meet GM standards. The GM Approved Refinish a r e o p e n . I m p r o p e r a p p lic a t io n m a y in c r e a s e
Materials book GM P/N 4901M-D identifies the paint c h a n c e o f c o r r o s io n d a m a g e o r l i m i t t h e o p e r a t io n
systems you may use. Always refer to the latest o f m o v in g p a r t s , r e s u l t in g in p e r s o n a l in ju r y .
revision of the 4901 M-D book. All approved products,
including volatile organic compound (VOC) - C a u t io n : F o a m s o u n d d e a d e n e r s m u s t b e r e m o v e d
compliant regulations are listed in the system approach f r o m a r e a s w ith in 1 5 2 .4 m m ( 6 in ) o f w h e r e f la m e
recommended by the individual manufacturer. Refer is t o b e u s e d f o r b o d y r e p a ir s . W h e n r e in s t a llin g
to the manufacturer’s instructions for the detailed f o a m s o u n d d e a d e n e r s , a v o i d in h a lin g f u m e s
procedures for materials used in the paint system in a s b o d ily i n ju r y m a y r e s u lt.
the painting repairs of rigid exterior surfaces. All C a u t io n : A p p r o v e d s a f e t y g la s s e s a n d g lo v e s
components of an approved paint system have been s h o u l d b e w o r n w h e n p e r f o r m i n g t h is p r o c e d u r e
engineered in order to ensure proper adhesion to r e d u c e t h e c h a n c e o f p e r s o n a l in ju r y .
between layers.
N o t ic e : The anti-theft label found on some major body
If necessary, spot repairs or color blending in an open panels MUST be covered before performing any
panel can be done. However, do not blend clearcoat painting, rustproofing or undercoating procedures. The
in an open panel. Always apply clearcoat to the mask must also be removed following those
next break point (body side molding, feature line, or procedures. Failure to follow these precautionary
the next panel.) steps may result in liability for violation of the Federal
Do not mix paint systems or substitute a product of Vehicle Theft Prevention Standard, and subject the
1 manufacturer for another manufacturer’s product. If vehicle owner to possible suspicion that the part was
incompatible products are used together the stolen.
following problems may occur: Anti-corrosion materials providing rust resistance are
• Lifting of primer coats caused by overly aggressive used on the interior and the exterior surfaces of
solvents in subsequent layers the metal panels. These materials include the following
• Loss of adhesion between layers due to metals:
incompatibility of resin systems
• Solvent popping or pinholing due to inappropriate
solvent selection
• Poor through-curing due to incompatible hardener
resins or insufficient reactivity
• Gloss reduction due to incompatible resins and/or
solvents
• Poor color accuracy due to pigment interactions
with incompatible resins and/or solvents
• Film defects (craters, blisters, orange peel loss of
gloss) due to the use of inferior quality raw
materials in incompatible products

142064

• One-sided galvanized zinc

• Two-sided galvanized zinc
• Zinciron alloy steels
These treated metals are used on the following
components:
• The fenders
• The doors
• The quarter panels
• The rocker panels
® The lids
• The floor pans
• The wheelhousings
• Other critical parts
Metal conditioners and primers are used on the
interior and the exterior surfaces along with protective
waxes on the interior surfaces in the areas where
moisture might accumulate. Sealers are applied along
the exposed joints and the moisture-repelling
asphaltic sound deadeners are applied inside the
wheel wells, the doors, and on some underbody
components.
These sealers are intended to prevent water and dust
from entering the vehicle and also are anti-corrosion
barriers. Sealers are applied to such areas as
rear compartment lid hem flanges, wheelhouse,
quarter outer, floor, cowl3 roof, and various other panel
to panel attaching points. The originall y sealed
joints are obvious and any damage to these sealed
locations should be corrected by resealing. Attaching
points of new replacement panels shoul d be
resealed. Replacement lids and doors will also require
sealing in the hem flange areas. :
Flanged joints, overlap joints, and seams should be
sealed using a quality sealer of medium-bodied
consistency. The sealer used must reta i n its flexible
characteristics after curing and be paintable.

142051

Any procedure that disturbs these special treatments,

such as panel replacement or collision damage
repair operations, may leave the metal unprotected
and result in corrosion. Proper recoating of these
surfaces with service-type anti-corrosion material is
essential.
Metal conditioners and primer coatings are applied to
al l metal panels at the time of vehicle manufacture.
After repair and/or replacement parts are installed, all
accessible bare metal surfaces must be treated
with metal conditioner and reprimed using a zinc
chromate primer. This operation is to be performed
prior to the application of sealers, waxes; deadeners,
and antirust compounds. Refer to Basecoat/Clearcoat 142047

P a in t S y s te m s .
Open joints which require bridging of the sealer in
order to close a gap should be sealed using a
heavy-bodied caulking material. Follow the label
directions for the material selected.
Color application may be required in order to restore Anti-corrosion compounds are light-bodied materials
repaired areas such as hood, fenders, doors, quarters, designed to penetrate between metal-to-metal
lid, roof, engine compartment, underbody, and inner surfaces, such as pinch weld joints, hem flanges, and
panels to original appearance. When this is necessary, integral panel attaching points where metal surfaces
conventional refinishing preparation, undercoat are difficult to coat with conventional undercoating
buildup, and color application techniques should be materials, and are inaccessible for painting. Material
followed. Refer to Basecoat/Glearcoat Paint Systems. suited for this type of application is GM P/N 12346225
Anti-Corrsion Compound Clear (Oil Base) or
equivalent. Conventional undercoating is
recommended in order to coat large areas such as
replacement door and quarter outer panels, floor pan
sections, lids, hoods, fenders, etc. During undercoating
operations, care should be taken to prevent the
material from being sprayed into door and quarter
panel hardware mechanisms such as door locks, glass
run channels, window regulators, and seat belt
retractors. On the underbody, the material should not
be applied to any moving or rotating part, energy
absorbing bumper components, or shock absorbers.
After undercoating, ensure that all body drain holes are
open. Refer to B a s e c o a t/C le a r c o a t P a in t S y s te m s
for the sequence of application steps for anti-corrosion
materials.

Deadener materials (spray-on type) are used on

various metal panels in order to provide corrosion
resistance and joint sealing. They control the general
noise level inside the passenger area of the vehicle.
When deadeners are disturbed because of damage,
are removed during repair operations, or a new
replacement panel is installed, the deadener material
must be replaced by a service equivalent material.
The application pattern and location of deadener
materials can be determined by observing the original
production installation.

Cleaning of the interior and underbody panel surfaces

is necessary when original galvanized or other
anti-corrosion materials have been burned off during
welding or heating operations. Removal of the residue
from burning will require additional care in such
areas as interior surfaces of box-type construction and
when configurations of the metal panels limit access
to interior surfaces. One or more of the following
methods will remove the residue.
• Sandblasting is an excellent method for cleanup
and preparation of open joints, underbody
components, and hem flange areas. Sandblasting
is most effective and should be used.
• When access is possible, scraping with a putty
knife or scraper can be used.
• A jet of compressed air will remove most residue
and could be effective in a limited access areas.
Paint Identification Repair Instructions
Introduction
Clearcoat Repair w/o Repainting
C a u tio n : E x p o s u re to is o c y a n a te s d u r in g p a in t
p re p a r a tio n a n d a p p lic a tio n p ro c e s s e s c a n c a u s e N o t i c e : Removing more than 0.5 mils of the clearcoat
s e v e re b r e a th in g p ro b le m s . R e a d a n d fo llo w a ll can result in early paint failure. The clearcoat
o f th e in s tru c tio n s fro m th e m a n u fa c tu r e r s o f contains ultraviolet screeners. Do not finesse sand
p a in tin g m a te ria ls , e q u ip m e n t, a n d p r o te c tiv e g e a r. more than what is required to remove the defect.

Important: Always refer to the GM Approved Important:

Refinish Materials book GM P/N 4901 M-D. This book • Avoid washing vehicles in direct sunlight.
identifies the paint systems you may use. • Avoid using strong soaps or chemical detergents.
The basecoat/clearcoat paint is factory applied in the • Use brushless type automatic car wash
following 4 layers in order to give the finish a high equipment.
gloss look:
• Avoid using products containing acids (unless
1. A cathodic immersion primer specified in order to correct a condition such as
2. A primer/surfacer rail dust).
3. A basecoat • Do not use brushes or brooms in order to remove
4. A clear top coat (clearcoat) snow or ice from vehicles in storage or on lots.
• Cleaning agents and water should be dried
promptly and not allowed to dry on the surface.
Drying with a soft chamois is recommended.
• Standing rinse water should be dried promptly and
not allowed to dry on the surface.
Drying with a soft chamois is recommended.
• Do not polish vehicles unless a surface condition
exists that can only be corrected by polishing.
Refer to C le a r c o a t R e p a ir S p e c ific a tio n s - M e g u ia r
P r o d u c ts or C le a r c o a t R e p a ir S p e c ific a tio n s -
3 M P ro d u c ts .
• If a surface condition does exist, the repair
approach should be one of less is best (the very
least it takes to correct the condition).
• Avoid removing too much clear coat (whenever
possible, use paint gauges before, during and
after polishing). Refer to P a in t G a u g e s .
• Use only the products recommended in this
65485 procedure (or their equivalent). Refer to C le a r c o a t
R e p a ir S p e c ific a tio n s - M e g u ia r P ro d u c ts or
Legend
C le a r c o a t R e p a ir S p e c ific a tio n s - 3 M P ro d u c ts .
(1) Vehicle Identification Number • Ensure that any power polishing equipment does
(2) Engineering Model Number (Vehicle Division, not exceed the requirements in the polish
Vehicle Line and Body Style) manufacturers recommendations. The final
(3) Interior Trim and Decor Level process step typically uses an orbital type polisher
(4) Exterior (Paint Color) WA Number with speeds of 1,500-2,000 RPM. Refer to
(5) Paint Technology C le a r c o a t R e p a ir S p e c ific a tio n s - M e g u ia r

(6) Special Order Paint Colors and Numbers P ro d u c ts or C le a r c o a t R e p a ir S p e c ific a tio n s - 3 M

P ro d u c ts .
(7) Vehicle Option Content
• Do not use wax or silicone type products in order
Refer to Service Parts Identification in General to hide swirl marks (this damage will reappear
Information in order to identify the type of top coat on later and cause customer dissatisfaction).
the vehicle. This label contains all paint related • Specific conditions on the paint (environmental
information for the vehicle. This includes paint damage, rail dust, etc.) may be corrected by:
technology, paint codes, trim level, and any special • Refer to E n v iro n m e n ta l F a llo u t (A c id R a in ).
order paint colors.
• Refer to R a il D u s t D a m a g e R e p a ir.
 1. Thoroughly wash the repair area with Liquid Wash Slight Clearcoat Damage — Wet Sanding,
and Wax GM P/N 1052870 or the equivalent. Finesse Polishing
2. Readings of the paint film build should be taken N o t ic e : Removing more than 0.5 mils of the clearcoat
prior to the operation. Refer to P a in t G a u g e s . can result in early paint failure. The clearcoat
3. App ly a small amount of the appropriate material contains ultraviolet screeners. Do not finesse sand
to repair area and smear evenly with the pad. more than what is required to remove the defect.
Refer to C le a r c o a t R e p a ir S p e c ific a tio n s - M e g u ia r
Important: Always refer to manufacture’s packaged
P ro d u c ts or C le a r c o a t R e p a ir S p e c ific a tio n s -
instructions for the detailed procedures of materials
3 M P ro d u c ts .
used for compounding or polishing.
4. With the polisher running at approximately
1 . Select a small test area on the damaged panel.
1,500-2,000 RPM, polish the repair area.
Keep the pad flat against the panel while applying 2. Readings of the paint film build should be
heavier pressure for 4 -6 seconds. Then, polish taken prior to the operation. Refer to
with lighter pressure for 6 -8 seconds. Feature P a in t G a u g e s .
lines and panel edges should be hand-rubbed in 3. Wet sand the damaged area using an ultra-fine
order to avoid burn-through. sandpaper and rubber sponge sanding block.
5. Inspect the repair area frequently. Add more of Refer to the manufacturer’s instructions for
the appropriate material as needed. detailed procedures for the materials used in the
repairs. During the wet sand process:
6 . Always blend or feather the outer edges of the
repaired area. 3.1. Use ample amounts of water.
7. After buffing, inspect the repaired area. 3.2. Work slowly in order to prevent removing
too much clearcoat.
8 . If swirls are still visible, repeat the buffing
procedure. 4. Remove the excess water with a rubber squeegee
and inspect the area. If wet sanding has repaired
9 . Clean the repaired area using a clean soft,
the damage, continue the sanding procedure
non-scratching cloth with a 50/50 mixture of
on the entire panel.
Isopropyl Alcohol and water.
5. Apply a finesse-type polish with a foam pad.
10. If sanding is required, refer to C le a r c o a t R e p a ir
Remove any swirl marks with a dual action
S p e c ific a tio n s - M e g u ia r P ro d u c ts or C le a rc o a t
orbital polisher and foam pad. Refer to C le a r c o a t
R e p a ir S p e c ific a tio n s - 3 M P ro d u c ts .
R e p a ir S p e c ific a tio n s - 3 M P ro d u c ts or C le a r c o a t
R e p a ir S p e c ific a tio n s - M e g u ia r P ro d u c ts . If
Environmental Fallout (Acid Rain) (during the repair) you suspect or observe that
Since the severity of the condition varies from area to etching has penetrated into the basecoat,
area, proper diagnosis of the damage extent is too much clearcoat has been removed during
critical to the success of repairs. Perform diagnosis sanding or base color is transferred to pad during
under high intensity fluorescent lighting, on horizontal polishing, the affected areas may require
surfaces (hood, roof panel, rear compartment lid) clearcoat/basecoat application or refinishing.
after the surfaces have been properly cleaned. There Refer to B a s e c o a t/C le a r c o a t P a in t S y s te m s .
are 3 basic types of acid rain damage: 6 . Polish the entire vehicle after all damage has
Surface Level Contamination: May be repaired by been repaired.
simply washing the vehicle, cleaning the surface
with a silicone, wax and grease remover, neutralizing
acidic residue and finesse polishing. Refer to
Surface Level Contamination Repair in this procedure.
Clearcoat Etching: Slight etching still noticeable
after the above washing and finesse polishing
procedure. Refer to Slight Clearcoat Damage — Wet
Sanding, Finesse Polishing in this procedure.
Basecoat Etching: Severe etching beyond the
clearcoat into the basecoat. Refer to
B a s e c o a t/C le a r c o a t P a in t S y s te m s .
Surface Level Contamination Repair Paint Thickness Gauges
N o t ic e : Removing more than 0.5 mils of the clearcoat • 147-5437-ETG Standard Model
can result in early paint failure. The clearcoat • 147-5437-ETG-P Standard model with print
contains ultraviolet screeners. Do not finesse sand option.
more than what is required to remove the defect.
• 147-5437-N-ETG-N Non-ferrous model for
Important: Always refer to manufacture’s packaged aluminum panels
instructions for the detailed procedures of materials • 147-5437-NP-ETG-NP Non ferrous model with
used for compounding or polishing. print option
1. Thoroughly wash the repaired area with Liquid • 147-54437-SD-ETG Steel and aluminum gauge
Wash and Wax GM P/N 1052870.
2. Dry the area thoroughly. Clearcoat Thickness
3. Clean the affected area with silicone, wax and The clearcoat on the vehicle is typically
grease remover. 0.059- 0.078 mm (1.5-2 mils; 0.0015-0.0020 in.)
4. Neutralize left over acidic residue by cleaning thick. The clearcoat contains ultraviolet screeners.
damaged areas with mixture of baking soda Removing more than 0.5 mils (0.019 in.) of the
and water (1 tablespoon of baking soda per clearcoat may result in early paint failure.
1 quart of water). Rinse thoroughly and dry the
panel completely. Rail Dust Damage Repair
5. Apply finesse-type polish with a foam panel. If
C a u t io n : A p p r o v e d s a f e t y g la s s e s a n d g lo v e s
damage has been repaired, remove any swirl
s h o u l d b e w o r n w h e n p e r f o r m i n g t h is p r o c e d u r e
marks with dual action orbital polisher and foam
t o r e d u c e t h e c h a n c e o f p e r s o n a l in ju r y ..
pad. Refer to C le a r c o a t R e p a ir S p e c ific a tio n s -
3M Products or Clearcoat Repair Specifications - Important: If rail dust has penetrated into the
Meguiar Products. basecoat, the panel requires refinishing. Ensure all the
6. If some damage remains, refer to Slight Clearcoat rail dust has been removed prior to refinishing or
Damage—Wet Sanding, Finesse Polishing in this the rust spots will return.
procedure. Rail dust damage comes from the tiny iron particles
produced from the friction between the train wheels
Paint Gauges and the track. It can also be deposited on vehicles
if stored near any operation producing iron dust
Use a paint gauge before, during and after the (i.e., steel ore yards). This dust can either lay on top
sanding process in order to accurately measure how of, or embed into the paint surface. It is usually
much clearcoat has been removed. Paint gauges diagnosed as bumps in the paint surface or rust
measure the total thickness of the finish and when colored spots in the paint.
used, determine how much clearcoat has been
removed during the repair process. Paint gauges range 1. Move the vehicle to a cool shaded area and
from magnetic pull type to sophisticated electronic ensure the vehicle surfaces are cool during
types and are available from a variety of sources. The the removal process.
older magnetic type gauges, at best have a 5 percent 2. Thoroughly wash the repair area with Liquid Wash
accuracy range and are not sensitive enough to and Wax GM P/N 1052870 or the equivalent.
detect removal of 0.020 mm 0.5 mil; (0.0005 in) 3. Wipe the area dry.
clearcoat. The newer type magnetic gauges have 4. Glean the affected area with silicone, wax and
improved accuracy ranges. Most gauges are confined grease remover.
to checking either ferrous metal (steel) or non
ferrous metal (aluminum) panel. At this time, there are 5. Perform the removal process according to the
no viable gauges for reading film thickness on manufacturer’s directions of the type of repair
composite (SCM Doors, RIM Fenders) panels. The material used (Gel Type Oxalic Acid or Clay Type
more sophisticated (ETG) electronic paint thickness Non-Acid Based). If, upon inspection, some
gauges digital type gauges are able to read film particles are still present, the process may be
thickness on both ferrous and non-ferrous metal panel. repeated. If the damage has been repaired,
Digital (ETG) gauges may have an accuracy range complete the repair to the entire panel.
of 1 percent and include thickness standards for 6. Polish the entire panel after the removal process.
recalibration. The following paint thickness gauges are Refer to Clearcoat Repair Specifications -
available. Call I- 8OO-GM-TOOLS for information. 3M Products or Clearcoat Repair Specifications -
Meguiar Products. If small pits remain in the
clearcoat after all of the damage has been
repaired, refer to Clearcoat Repair w/o
Repainting.
Frame and Under body
Specifications
Fastener Tightening Specifications
Specification
Appli cation Metri c :J;ngiii
Engine Protection Shield to Frame Rail Bolts 35‘N-m 26 so ft
Platform Hitch to Frame Rail Bolts 100 N-m 74 Ib ft
Running Board Nuts 23 N-m 17 1b ft
Tow Hook to Frame Rail Bolts 60 N-m 441b ft

GM SPO Group Numbers

Application GM SPO Group Number
Cushion Body Bolt 9.023
Retainer Body Bolt 9.023
Bolt Body 9.008
Retainer 9.023
Crossmember Trans Support 4.081
Frame Chassis 7.003
Trailer Hitch 8.903
Trailer ! 'M c h Brace . 7.836
Trailer Hitch Reinforcement 7.068

Yield Strength of Different Metals

Specification
Metal Types kPa PS]
SAE J-1392-050 344,750 50,000
SAE J-1392-080 551,600 80,000
SAE 1027 (Heat Treated) 758,400 110,000

Welding Table
Materials Used SAE J-1932-050 J-*?£32-080
Process GMAW SMAW S:vAW
El ectrode E70S-3 E7016, E7018 El 1018
Minimum Yield of Electrode 413,700 kPa (60,000 psi) 413,700 kPa (60,000 psi) 668,815 kPa (97,000 psi)
Chamfer Used When Cutting
Away the Sides of a Crack to 60° 90° 90°
Be Welded
 Electrode Table
Electrodes E-7011, E-7016 E-7018, E-11Q18
Flat Welding
Available Sizes Current Range (Amps) Arc Vol tage
5/64 in x 9 in 30-60 20-22
5/32 in x 12 in 45-80 2 9-23
1/8 in x 14 in 80-115 .21-23
5/32 in x 14 in 125-165 22-24
3/16 in x 14 in 160-200 22-24
7/32 in x 18 in 200-250 .23-25
1/4 in x 18 in 250-320 23-25
5/16 in x 18 in 325-400 24-28
Overhead Welding
Avail able Sizes Current Range (Amps) Arc Voltage
3/32 in x 12 in 45-75 20-22
1/8 in x 8 in 80-125 20-24
5/32 in x 14 in 120-190 21-24
3/16 in x 14 in 150-240 21-24

Plug Weld Table

Thickness of Material Diameter of Plug Depth of Plug

6 mm (1/4 in) 19 mm (3/4 in) 6 mm (1/4 in)
10 mm (3/8 in) 25 mm (1 in) 10 mm (3/8 in)
13 mm (1/2 in) 29 mm (1 1/8 in) 11 mm (7/16 in)
16 mm (5/8 in) 32 mm (1 1/4 in) 13 mm (1/2 in)
19 mm (3/4 in) 35 mm (1 3/8 in) 14 mm (9/16 i n)
25 mm (1 in) 38 mm (1 1/2 in) 14 mm (9/16 in)
 Alignment Checking
Conditions Action
Frame is out of alignment. Replace or weld and reinforce the rail. Ream the bolt holes. Replace with larger
bolts if necessary. Retighten the bolts.
The front or the rear axle has shifted. Replace or weld and reinforce the raii.
Incorrect wheel a l ignment. Refer to M e a s u r i n g W h e e l A l i g n m e n t ( C M o d e l ) or M e a s u r i n g W h e e l A l i g n m e n t
( K M o d e l ) in Wheel Alignment.

C hecking.Fram e A lig n m e n t The easiest way to inspect the frame alignment is with
gauges that are made for this purpose. Detailed
The main components of the frame are the side rails instructions are normally supplied with the gauges at
and the crossmembers. The rails carry the load. the time of purchase. There are no instructions for
The crossmembers stabilize the rails. gauge use in the manual.
The 5 types of frame misalignment are. the following: Whether you inspect the alignment with or without
• Sag gauges, park the vehicle on a level section of floor.
Certain conditions call for preliminary inspections
• Buckle
before inspecting the frame. Suspension or axle
• D iam on d problems may make it appear that the vehicle frame is
• Sidesway out of alignment. If an axle has shifted, diamond or
sidesway may appear to exist when neither do exist. A
• Twist weak spring may make the vehicle appear to have a
A misaligned frame rail may move in the following twisted frame.
directions from w h e re th e fra m e rail should be: A visual inspection of the top and the bottom flanges
• Forw ard of each rail may reveal the specific area where
the sag or the buckle exist. In the case of a sag,
• Up wrinkles may appear on the top of the upper flange.
• D ow n The wrinkles are definite evidence of sag. Wrinkles on
the bottom of the lower flange are definite evidence
• T o th e side
of buckle.
Body and Accessories Frame and Underbody 8-1229
Frame Conditions
Sag
Condition Action
Loads greater than the frame i s Straighten and reinforce the frame. Refer to F r a m e S t r a i g h t e n i n g D e s c r i p t i o n .
designed to carry causes sag.
Uneven load distribution causes sag.
Abrupt changes in the section
modulus.
Improper body, or accessory
mounting, which may include the
following:
• Holes dril led i n the flange of the
frame rail .
® Too many holes in the web
section of the rail.
® Holes in the web section which
are too close to each other.
• Four or more holes in the same
vertical line of the rail web.
® Welds on the flange, particularly
across the flange or along
its edge.
• Cutting holes in the rail with
a torch.
• Cutting notches anywhere on
the rails.
A collision involving the vehicle
causes the following conditions:
• Sag
• Buckle
• Sidesway
• Diamond
The use of equipment for which the
frame has not been designed or
reinforced causes the following
conditions:
• Sag
• Buckle
■’ Sidesway
 Buckle
Condition Action
Using equipment like snow plows for Straighten and reinforce the frame. Refer to F r a m e S t r a i g h t e n i n g D e s c r i p t i o n .
which the frame was not designed.
A collision involving the vehicle.
A fire involving the vehicle.
Abrupt changes in section modulus.
Improper body, or accessory
mounting, which may include the
following;
® Holes drilled in the flange of the
frame rail.
• Too many hol es in the web
section of the rail.
• Holes in the web section which
are too close to each other.
® Four or more holes in the same
vertical line of the rail web.
® Welds on the flange, particularly
across the flange or along
its edge.
• Cutting holes in the rail with
a torch.
® Cutting notches anywhere on
the rails.

S id e s w a y
' dition Action
A collision involving the vehicle. Straighten and reinforce the frame. Refer to F r a m e S t r a i g h t e n i n g D e s c r i p t i o n .
A fire involving the vehicle.
The use of equipment such as snow
plows for which the frame was neither
designed nor properly reinforced.
Abrupt changes in section modulus.
Improper body, or accessory
mounting, which may include the
following:
• Holes drilled in the flange of the
frame rail.
• Too many holes in the web
section of the rail.
• Holes in the web section which
are too close to each other.
• Four or more holes in the same
vertical line of the rail web.
• Welds on the flange, particularly
across the flange or along
its edge.
® Cutting holes in the rail with
a torch,
® Cutting notches anywhere on
the rails.
 Diamond
Conditions Action
A collision involving the vehicle. Straighten and reinforce the frame.
Towing another vehicle with a chain Refer to F r a m e S t r a i g h t e n i n g D e s c r i p t i o n .
attached to one corner of the frame.

Twist
Condition Action
An accident or collision involving the Straighten and reinforce the frame.
vehicle. Refer to F r a m e S t r a i g h t e n i n g D e s c r i p t i o n
Operating the vehicle on very rough
terrain.

Improper Tracking
Conditions Action
The frame is out of alignment. Replace or weld and reinforce the rail. Ream the bolt holes. Replace with larger
bolts if necessary. Retighten the bolts.
The front or rear axle has shifted. Replace or weld and reinforce the rail.
The wheel alignment is incorrect. Refer to M e a s u r i n g W h e e l A l i g n m e n t ( C M o d e l ) or M e a s u r i n g W h e e l A l i g n m e n t
( K M o d e l ) in Wheel Alignment.

Cracks in Web of Rails

Conditions Action
Loose crossmember attaching bolts. Replace or weld and reinforce the rail. Ream the bolt holes. Replace with larger
bolts if necessary. Re-tighten the bolts.
Concentration of stress that may Replace or weld and reinforce the rail.
result from many different factors.
Refer to M i n i m i z i n g F r a m e S e r v i c e
D e s c r ip tio n .
Frame Conditions - Sag

Condition Action
Loads greater than the frame is Straighten and reinforce the frame. Refer to F r a m e S t r a i g h t e n i n g D e s c r i p t i o n Frame
designed to carry causes sag. Straightening Description.
Uneven load distribution causes sag.
Abrupt changes in the section
modulus.
Improper body, or accessory
mounting, which may include the
following:
• Holes drilled in the flange of the
frame rail.
• Too many holes in the web
section of the rail.
® Holes in the web section which
are too close to each other.
• Four or more holes in the same
vertical line of the rail web.
• Welds on the flange, particularly
across the flange or along
its edge.
• Cutting holes in the rail with
a torch.
• Cutting notches anywhere on
the rails.
A collision involving the vehicle
causes the following conditions:
• Sag
• Buckle
• Sidesway
• Diamond
The use of equipment for which the
frame has not been designed or
reinforced causes the following
conditions:
• Sag
• Buckle
• Sidesway
Body and Accessories Frame and Underbody 8-1233
Frame Conditions - Buckle

Condition Action
Using equipment like snow plows for Straighten and reinforce the frame. Refer to Frame Straightening Description Frame
which the frame was not designed. Straightening Description.
A collision involving the vehicle.
A fire involving the vehicle.
Abrupt changes in section modulus.
Improper body, or accessory
mounting, which may include the
following:
• Holes drilled in the flange of the
frame rail.
• Too many holes in the web
section of the rail.
• Holes in the web section which
are too close to each other.
• Four or more holes in the same
vertical line of the rail web.
• Welds on the flange, particularly
across the flange or along
its edge.
• Cutting holes in the rail with
a torch.
• Cutting notches anywhere on
the rails.
Frame Conditions - Sidesway

Condition Action
A collision involving the vehicle. Straighten and reinforce the frame. Refer to F ra m e Straightening Description Frame
Straightening Description.
A fire involving the vehicle.
The use of equipment such as snow
plows for which the frame was neither
designed nor properly reinforced.
Abrupt changes in section modulus.
Improper body, or accessory
mounting, which may include the
following:
• Holes drilled in the flange of the
frame rail.
• Too many holes in the web
section of the rail.
• Holes in the web section which
are too close to each other.
• Four or more holes in the same
vertical line of the rail web.
• Welds on the flange, particularly
across the flange or along
its edge.
• Cutting holes in the rail with
a torch.
• Cutting notches anywhere on
the rails.

Frame Conditions - Diamond

Conditions Action
A collision involving the vehicle. Straighten and reinforce the frame.
Towing another vehicle with a chain Refer to F ram e Straightening Description Frame Straightening Description.
attached to one corner of the frame.

Frame Conditions - Twist

Condition Action
An accident or collision involving the Straighten and reinforce the frame.
vehicle. Refer to F ram e Straightening Description Frame Straightening Description
Operating the vehicle on very rough
terrain.
Frame Conditions - Improper Tracking

C onditions Action
The frame is out of alignment. Replace or weld and reinforce the rail. Ream the bolt holes. Replace with larger
bolts if necessary. Retighten the bolts.
The front or rear axle has shifted. Replace or weld and reinforce the rail.
Refer to M e a s u r i n g W h e e l A l i g n m e n t ( C M o d e l ) Measuring Wheel Alignment
The wheel alignment is incorrect. (C Model) or M e a s u r i n g W h e e l A l i g n m e n t ( K M o d e l ) Measuring Wheel Alignment
(K Model) in Wheel Alignment.

Frame Conditions - Cracks in

Web of Rails

Conditions Action
Loose crossmember attaching bolts. Replace or weld and reinforce the rail. Ream the bolt holes. Replace with larger
bolts if necessary. Re-tighten the bolts.
Concentration of stress that may Replace or weld and reinforce the rail.
result from many different factors.
Refer to M i n i m i z i n g F r a m e S e r v i c e
D e s c r i p t i o n Minimizing Frame Service
Description.
Repair Instructions
Frame S tra ig h te n in g D escrip tion Use controlled heat carefully. The major sources of
trouble are the following conditions:
Frame straightening can be complicated and usuall y 1. Too much heat.
requires special equipment. Only qualified technicians 2. Too little heat.
can perform the frame straightening procedure. 3. I mproper application of heat.
Perform a compl ete analysis of the condition of the Remove all the protective coating material before
frame before taking any steps to straighten the frame. using a flame to prevent a fire. Reapply the protective
Analyzing the cause of failure will determine the coating after the repair has been completed. Heat
correct sequence of steps in the repair. Refer to the frame with a large multi-hole heating tip. Use a
M i n i m i z i n g F r a m e S e r v i c e D e s c r i p t i o n . Use corrective neutral frame. Heat the area that will be stretched
while the frame is straightened. After sufficient
procedures to reverse the flow of damaging forces.
pressure has been exerted, heat the area to cause a
Apply pressure, in many cases, from different
slight checking, or silvery cracks, to appear on the
directions at the same time to reverse the flow of surface of the metal. Gradually increase the pressure
forces. while heating. Do NOT heat beyond 606°G (1200°F).
A red glow indicates that the material is overheated.
Overheating causes distortion and stretching.
Overheating causes a change in the characteristics of
the metal.
Body Mount Replacement (Extended Cab)
Remova! Procedure
P ro p erly support th e fra m e w h ile changing th e cab
mounts. L ow er th e side w h e re th e mount is placed in
order to provide c le ara n c e for th e mount w h e n
changing only 1 m ount.
1. R aise the vehicle on th e hoist.
2. Place the ja c k stands u n d er the cab on th e side
of th e vehicle w h e re th e m ounts are positioned.
3. Loosen th e m ounting bolts on the side w h e re the
m ounts a re positioned.
4. R e m o ve th e m ounting bolt (3).
5. R e m o ve th e low er cushion retainer (4).
6. R e m o ve th e low er cushion (5).
7. Low er th e hoist and support the cab w ith the
vehicle jacks.
8. R e m o ve th e u pp er cushion (6).
Installation Procedure
1. Install the upper cushion (6 ).
2. R a is e the fra m e on the hoist.
3. Install the low er cushion (5).
4. Install the low er cushion retainer (4).
N o tic e : R e fe r to F a s te n e r N o tice in C autio ns and
N otices.
5. Install th e m ounting bolt (3), and rem ove the jacks.
Tighten
T ighten th e m ounting bolts to 7 5 N-m (5 5 Ib ft).
6. L ow er th e hoist.
Body Mount Replacement (2 Door Utility)
Removal Procedure
P roperly support th e fra m e w hile changing th e cab
m ounts. L ow er th e side w h e re th e m ount is p laced in
o rd er to provide c le a ra n c e for th e m ount w hen
changing only 1 m ount.
1. R a is e th e vehicle on the hoist.
2. P lace the jac k stand s u nd er th e ca b on the side
of th e vehicle w h e re th e m ounts a re positioned.
3. Loosen the m ounting bolts on the side w h e re th e
m ounts are positioned.
4. R e m o v e the m ounting bolt (3).
5. R e m o v e the low er cushion re tain e r (4).
6. R e m o v e the low er cushion (5).
7. L ow er the hoist an d support th e cab with the
vehicle jacks.
8. R e m o v e the u p p er cushion (6).
Installation Procedure
1. Install th e u pp er cushion (6).
2. R aise the fra m e on th e hoist.
3. Initially th e low er cushion (5).
4. Install th e low er cushion retainer (4).
N o tic e : R e fe r to F a s te n e r N o tice in C autions and
N otices.
5. Install th e m ounting bolt (3), an d rem ove th e jacks.
Tighten
T ig h ten th e m ounting bolts to 7 5 N-m (5 5 Ib ft).
6. L ow er th e hoist.
Body Mount Replacement (Pickup)
Removal Procedure
Properly support th e fra m e w hile changing the cab
m ounts. L ow er th e sid e w h e re th e m ount is p laced in
o rd er to provide cle ara n c e for th e m ount w hen
changing only 1 m ount.
1. R a is e the vehicle on th e hoist.
2 . P lac e th e jac k stands u n d er the ca b on the side
of th e v e h ic le w h e re th e m ounts a re positioned.
3. Loosen the m ounting bolts on th e side w h e re the
m ounts are positioned.
4. R e m o v e th e m ounting bolt (3).
5. R e m o ve th e lo w e r cushion re tain e r (4).
6. R e m o ve th e lo w e r cushion (5).
7. L ow er the hoist and support the ca b with the
vehicle jacks.
8. R e m o ve th e u pp er cushion (6).
Installation Procedure
1. In s ta ll th e u pp er cushion (6 ).
2. R aise th e fra m e on th e hoist.
3. Initially th e low er cushion (5).
4. Install th e low er cushion retainer (4).
N o t ic e : R e fe r to F a s te n e r N o tice in C a u tio n s and
N otices.
5. Install th e m ounting bolt (3), and re m o ve the jacks.
T ig h te n
T ighten th e m ounting bolts to 7 5 N -m (5 5 Ib ft).
6. L ow er th e hoist.
Body Mount Replacement (Grew Cab)
Removal Procedure
P ro p e rly support the fra m e w hile changing the cab
m ounts. L ow er the side w h e re the m ount is p laced in
ord er to provide cle ara n c e fo r the m ount w hen
changing only 1 m ount.
1. R aise th e vehicle on th e hoist.
2. P lace th e ja c k stands u nd er th e cab on th e side
of the vehicle w h e re the m ounts are positioned.
3. Loosen th e mounting bolts on the sid e w h e re the
m ounts a re positioned.
4. R e m o v e th e m ounting bolt (3).
5. R e m o v e th e low er cushion retainer (4).
6. R e m o ve the low er cushion (5).
7. Low er th e hoist an d support th e cab with the
vehicle jacks.
8. R e m o ve the upper cushion (6).
Installation Procedure
1. Install the upper cushion (6 ).
2 . Raise the frame on the hoist.
3. I nitially the lower cushion (5).
4. Install the lower cushion retainer (4).
N o t ic e : Refer to F a s t e n e r N o tic e in Cautions and
Notices.
5. Install the mounting bolt (3), and remove the jacks.
Tighten
Tighten the mounting bolts to 75 N-m (55 Ib ft).
6 . Lower the hoist.
Body Mount Replacement (4 Door Utility)
Removal Procedure
Properly support the frame while changing the cab
mounts. Lower the side where the mount is placed in
order to provide clearance for the mount when
changing only 1 mount.
1. Raise the vehicle on the hoist.
2. Place the jack stands under the cab on the side
of the vehicle where the mounts are positioned.
3. Loosen the mounting bolts on the side where the
mounts are positioned.
4. Remove the mounting bolt (3).
5. Remove the lower cushion retainer (4).
6. Remove the lower cushion (5).
7. Lower the hoist and support the cab with the
vehicle jacks.
8. Remove the upper cushion (6).
installation Procedure .
1. Install the upper cush ion (6).
2. Raise the fram e on the hoist.
3. Initially the lower cushion (5).
4. Install the lower cushion retainer (4),
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the mounting bolt (3), and remove the jacks.
Tighten
Tighten the mounting bolts to 75 N-m (55 Ib ft).
6. Lower the hoist.
Body Mount Replacement (Suburban)
Removal Procedure
Properly support the frame while changing the cab
mounts. Lower the side where the mount is placed in
order to provide clearance for the mount when
changing only 1 mount.
1. Raise the vehicle on the hoist.
2. Place the jack stands under the cab on the side
of the vehicle where the mounts are positioned.
3. Loosen the mounting bolts on the side where the
mounts are positioned.
4. Remove the mounting bolt (3).
5. Remove the lower cushion retainer (4).
6. Remove the lower cushion (5).
7. Lower the hoist and support the cab with the
vehicle jacks.
8. Remove the upper cushion (6).

277640
 Installation Procedure
1. Install the upper cushion (6).
2. Raise the frame on the hoist.
3. Initially the lower cushion (5).
4. Install the lower cushion retainer (4).
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the mounting bolt (3), and remove the jacks.
Tighten
Tighten the mounting bolts to 75 N-m (55 Ib ft).
6. Lower the hoist.

277640

Trailer Hitch Replacement

Removal Procedure
1. Remove the plate bracket (4), if equipped, from
the hitch platform (1) bolts and the nuts (3).

265017
 2. Remove the license plate bracket assembly, if
equipped, from the (5) hitch platform.
3. Remove the (6) bolts, the (1) washers, and the
nuts from the hitch platform and the frame rail.
4. Remove the hitch platform from the vehicle.

Installation Procedure
1. Install the (1) hitch platform to the vehicle.

265017

Notice: Refer to Fastener Notice in Cautions and I

Notices.
2. Install the hitch (6) bolts and the (1) washers
through the frame rails and with the (2) nuts.
Tighten
Tighten the hitch to the frame bolts to
100 N-m (74 Ib ft).
3. Install the license plate bracket assembly, if
equipped, to the hitch platform.
4. Install the bolts and the nuts.

265020
 Tow Hook Replacement
Removal Procedure
1. Remove the tow hook (3) bolts from the frame rail.
2. Remove the (2) tow hook and the (1) plate
from the vehicle.

Installation Procedure
1. Install the (2) tow hook and the (1) plate to the
frame rail.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the frame rail to the tow hook (3) bolts.
Tighten
Tighten the frame to the tow hook bolts to
60 N-m (44 Ib ft).

265004

Engine Protection Shield Replacement

Removal Procedure
1. Remove the four frame to the shield bolts.
2. Remove the shield from the vehicle.

265002
Installation Procedure
1. install the shield to the vehicle.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the four frame to the shield bolts.
Tighten
Tighten the frame to the shield bolts to
35 N-m (26 Ib ft).

Running Board Replacement

Removal Procedure
1. Remove the bolts that attach the running board
end caps to the body.
2. Remove the nuts that secure the running board to
the T-bolts and the brackets.
3. Remove the running boards from the vehicle.

4. Remove the nuts that secure the running board

extensions and the mat to the running
board frame.
5. Remove the extensions and the mat from the
running board frame.

264956
 Installation Procedure
1. Install the mat and the extensions to the running
board frame.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the nuts that secure the mat and the
extensions to the running board frame.
Tighten
Tighten the nuts to 1 N-m (9 Ib in).
3. Install the running board assembly to the vehicle.
4. Install the nuts that secure the running boards.
Tighten
Tighten the nuts to 23 N-m (17 Ib ft),
5. Install the bolts that secure the end caps to the
vehicle.
Tighten
Tighten the bolts to 17 N-m (13 Ib ft).

Damaged Cage Nut Service

Removal Procedure
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Remove the battery ground (negative) cable.
2. Remove the frame bolt (2) from the frame
crossmember nut.

307714

Important: The frame crossmember nut retainer will

be reused if not damaged from the stripped out bolt.
1
3. Break away the spot welds (1) on one side of the
frame crossmember nut retainer with an air chisel.
4. Lift one side of the frame crossmember nut
retainer (enough to remove the frame
crossmember nut).
5. Remove the frame crossmember nut.

307715
Installation Procedure
1. Install the frame crossmember nut (2). 1

307715

2. Install the lower frame crossmember nut retainer

into place to insure proper placement and working
1
condition of the frame crossmember nut.
3. Install the spot weld (3) frame crossmember nut
retainer in the original location.
4. Clean and prepare the welded surfaces.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the new frame bolt to the frame
crossmember nut.
Tighten
Tighten the new frame bolt to 180 N*m (133 Ib ft).
6. With a pressure pot apply the anticorrosion
compound GM P/N 12346225 or equivalent
and coat the inside of the repair area through any
access hole thoroughly.
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
7. install the battery ground (negative) cable. 307714
Description and Operation
Datum Description Centerline Description

264979

A datum is an imaginary horizontal plane that runs

264982
below and parallel to the vehicle. Height dimensions
are calculated at right angles from the datum to A centerline is an imaginary vertical plane that is
the given control or reference points on the underbody. perpendicular to the length of the datum plane through
The company that develops height dimensions the center of the vehicle. The centerline is any line
determines the location of the datum based on the drawn through the center of the vehicle’s datum. The
equipment being used. Therefore, different datum lines symbol for centerline is CL.
are established for the same vehicle. You can add
or subtract an equal amount from all height dimensions Length
and create a new datum line for your usage. Centerline length measurements are 3-dimensional
measurements. The three dimensions are the
following:
• Length, the distance between 2 points when the
height is parallel to the center plane.
• Height, the measurement is parallel to the
datum plane.
• Width, the measurement is parallel to the
center plane.
When reading dimension charts, horizontal width and
length dimensions of the underbody are shown as
viewed from the bottom of the underbody. Vertical
dimensions are shown from the side of the underbody
and use the datum plane as a base for all vertical
(height) measurements.
Centerline measurements are used with universal
measuring equipment.
Vertical Body Zero Line 4. Remove the protective coating on the frame in the
area of the repair. Open the bottom of the crack
2 mm (1/16 in) to allow good penetration of
the weld. Use a hacksaw blade.
5. Weld the frame with the proper electrode and the
proper welding techniques. Refer to Welding
Description.
6. Grind the weld smoothly on the inside and the
outside of the rail or the crossmember. Eliminate
the weld buildup or notches on the edge of
the flange. Apply the coating of protective material.

Welding Description
Using improper welding techniques causes many weld
and/or frame failures. The following information
points out potential areas of difficulty and provides
general guidelines for successful frame welding:
• Most weld failures occur at the end of the weld in
areas of the frame under high stress.
• Eliminate the ends of the weld by making a hole
264984 or slot in the part to be attached.
The vertical body zero line is a line drawn through the • Use a fillet weld around the slot or plug weld.
frame either at the forward or rearward torque box • Do not leave a notch at the end of a weld.
area of the frame. Do not overweld, especially areas of the frame that
receive high concentrations of stress.
Repairing Cracks Description Weld small cracks in a crossmember. Refer to
The following are 2 common types of cracks: Repairing Cracks Description.
Perform the following steps when welding:
• The straight crack, normally starts from the edge
of a flange. The straight crack will go across the Caution: Refer to Battery Disconnect Caution in
flange and through the web section of a rail, Cautions and Notices.
and continue through the other flange. The straight 1. Disconnect the battery.
crack may result from high concentrations of 2. The frame is covered with a protective wax
stress in small areas of the frame, excessive coating.
bending movement, and torsional loading. Refer
to Minimizing Frame Service Description. - Use a wire brush to remove any
concentration of wax before welding.
• Sunburst cracks radiate outward from a hole in
- Apply a new wax coating when done
the web area of a rail or crossmember. Sunburst
welding.
cracks are caused by high loads being applied at a
mounting bracket or crossmember which is not 3. Do not use oxyacetylene welding equipment.
properly attached to the rail. 4. Use electrodes with a smaller diameter.
Repair cracks separately when cracks occur the rail Make several passes. Do not make any more
and reinforcement at a particular area of the frame. passes than necessary.
The flanges react independently to prevent localized 5. Only use as much heat as is necessary to
stress concentration. Use a copper spacer between the achieve adequate penetration.
flanges of cracked base rail flanges and reinforcement 6. Make sure that the weld is free from craters and
flanges. undercuts.
Use a weld bead to provide a good, smooth radius 7. Remove the scale from each successive pass.
when repairing crossmember mounting flange cracks. 8. Grind the surface of the weld flush with the parent
Replace any damaged crossmember. material when repairing a crack.
Align the frame and level the rails before repairing 9. Do not weld across the flanges when mounting
the frame: any accessories.
1. Remove any equipment that interferes with 10. Do not weld within 19 mm (0.75 in) of a flange
access to the crack. when mounting any accessories.
2. Locate the extreme end of the crack and drill a 11. Leave at least 6 mm (0.23 in) between the end of
3 mm (0.12 in) hole. a weld and the edge of the part,
3. V grind the entire length of the crack from the 12. Do not weld the cast brackets to the frame.
starting point to the 3 mm (0.12 in) hole at the 13. Do not weld together the flanges of any cracked
extreme end. reinforcements and base rails.
14. Do not attach the ground cable to the engine. Frame Conditions Description
Connect the welding machine ground cables as
close to the working area as possible. Collapse
15. Keep the welding cables away from the vehicle The frame may appear out of alignment under certain
wiring. Avoid any direct contact between the conditions when another condition exists. Refer to
welding cables and any part of the vehicle. Checking Frame Alignment.

Running Board Description

The running boards are a dealer installed option that
are mounted on factory installed brackets. The
brackets are located under the vehicle.

Frame and Underbody Description

Frames
The frame structure is independent of the body. The
full frame extends the entire length of the vehicle.
It supports the engine, transmission and the body. The
suspension supports the weight of the frame. The
metal thickness of the frame varies depending on the
application and could be anywhere from 3 to 6 mm
thick. Frames are covered with a wax base coating for
rust protection.
All frames have body mounts welded to the structure.
Thick rubber insulators are positioned between the
body mounts and frame of the vehicle. These 3361
insulators absorb normal road noise and vibration
generated by the suspension. The condition that occurs when buckles appear on
The following terms are defined: more than one surface of the box section of the side
rail. Collapse is the condition that occurs when a
Section Modulus: A measure of the strength of a
section of the underbody or the frame structure has
frame based on the height of the side rails, the width of
been shortened in length.
the side rails, the thickness of the side rails, and the
shape of the side rails. The section modulus does not Diamond
account for the strength of the material used in the
frame.
Yield Strength:' A measure of the strength of the
material from which the frame is made. The yield
strength is the maximum load that can be placed on a
material and still return to the original shape. The
yield strength is measured in kPa (psi).
Resistance To Bending Movement (RBM): A
single measure of the frame strength that accounts for
the section modulus and the strength of the material
used.
Web: The vertical component of a channel-type
frame rail.
Datum: The plane of the underbody of the frame
from which all the vertical measurements begin.
Tram Length: The measurements that are
2-dimensional. The measurements are parallel to the
datum line.

3362

The condition where 1 side of the frame moves forward

or rearward. The diamond then causes the frame
structure to be out of square.
Sag Tracking
The alignment of the vehicle’s axles with each other.
A misaligned frame can cause improper tracking.
All the axles will be parallel to each other and all the
axles will be perpendicular to the centerline of the
frame when the vehicle is tracking correctly.
Twist

352966

A vertical misalignment that results in an incorrect

datum line. Kick-up occurs when both sides of
the frame are equally misaligned.
Sidesway
3383

The condition where the sides of the underbody plane,

datum, are not parallel. 1 rail slopes up while the
other rail slopes down.

Minimizing Frame Service Description

Frame service can be minimized by lessening
the concentration of stress in small areas of the frame.
Use vehicles only for the purposes for which they
were designed.
® Do not overload the vehicle.
• Load the vehicle evenly. Avoid localized loads.
• Do not operate the vehicle on extremely
rough terrain at excessive speeds.
® Determine the forces placed on a frame from the
operation of equipment when picking a frame for
a new vehicle or reinforcing a frame.
352967
Follow the recommended practices when repairing a
A section of the frame positioned to the left or right of frame. Follow the recommended practices when
the centerline when compared to the rest of the mounting a body or equipment on a frame.
vehicle. • Avoid sudden changes in the section modulus.
® Do not drill holes in the frame rail flanges.
• Space holes in the web section of a rail at least
13 mm (1/2 in) apart.
• Use existing holes whenever possible.
• Do not cut holes with a torch.
® Do not overheat the frame rails.
® Avoid welding on the flanges.
® Do not allow four or more holes to exist on the
same vertical line of the web.
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