Body Repair Manual 1463KB

1999Chevrolet Silverado

and GMC SierraPanel Identification .....................................................1-1

Radiator Support Assembly ........................................1-2

Door Frame Opening ....................................................1-3

Door Hinge Replacement .............................................1-8

Magnesium Instrument Panel Support ....................1-12

Steering Column Intermediate Shaft.......................1-13

Frame Service .............................................................1-14

Body Dimensions ........................................................1-17

Frame Dimensions ......................................................1-20

Appendix .....................................................................1-24

1999 Chevrolet Silverado/GMC Sierra Collision Repair 1-1

Panel Identification

Two

-Sid

ed G

alva

niz

ed S

teel

Th

erm

op

last

ic O

lefi

n

1-2 1999 Chevrolet Silverado/GMC Sierra Collision Repair

Radiator Support Assembly

The radiator support assembly is made of aluminumalloy. Minor damage can be repaired with ER-4043welding wire and 100 percent argon shielding gas.The upper tie-bar and vertical support portion ofthe radiator support assembly (Fig. 1.1) are bolt-oncomponents. They are available as part of theradiator support assembly, or can be orderedseparately.

Fig 1.1 — Aluminum radiator support

Upper tie-bar

Vertical support


Door Frame Opening

The door frame opening is a unique laserwelded design incorporating multiple metalthickness to ensure the structural integrity ofthe cab. The door frame can be replaced atfactory seams, but requires the removal of theroof panel, windshield and cab rear corner.Sectioning procedures have been developedas a more cost-effective alternative to completereplacement. The specific area to be sectionedis determined by the extent of the damage tothe vehicle.

Windshield Area SectioningSectioning of door frame in windshield areacan be performed 30mm (1-3/16 inches) abovethe third trim mounting hole. Follow generalsectioning procedures using a 50mm (2 inch)backing plate with plug welds located 15mm(19/32 inch) from the edge of the cut lines and a25mm (1 inch) overlap (Fig.␣ 1.2).

Important: Sectioning is only recommendedfor the outer panel. If any inner panel isdamaged beyond repair it should be replacedat factory seams.

General SectioningNotice: This procedure does not apply to thefront hinge pillar. See front hinge pillarsectioning procedure.

When sectioning the door frame opening inareas where there is no inner reinforcement, a100mm (4 inch) backing plate must be installedbehind the joint to ensure a solid and secureweld. Backing plates can be cut from the unusedportion of the door frame opening service part.The specific areas to be sectioned are deter-mined by the extent of damage to the vehicle.

Notice: To ensure a secure weld, sectioningjoints should have a gap of approximately oneand one-half times the thickness of the metal(Fig.␣ 1.3). Trim parts as necessary to achievethis. Make certain to plug weld backing platesto both the new and original sections. Thismay require drawing the plate flat against thesections using a screw to temporarily securethe joint for welding.

Fig.␣ 1.2 — Windshield area sectioning

Fig.␣ 1.3 — General sectiong sleeve

30mm

50mm

100mm(4 in)Backing Plate

Gap = one and one-half times the thickness of the metal


General Sectioning, continued

Notice: Sectioning should not take place inthe shaded areas (Fig. 1.4). Sectioning inthese areas may compromise the structuralintegrity of the vehicle.

— REMOVE OR DISCONNECT —

1 Remove all related panels and components.2 Visually inspect and restore as much of the

damage as possible to factory specifications.3 Remove sealers, sound deadeners and anti-

corrosion materials as necessary.4 After pulling and straightening operations

have been completed, and before removal ofdamaged panel, check, measure andcompare the service part to original part tochoose the areas where sectioning can bestbe performed.

Fig.␣ 1.4 — Laser welded areas␣ ␣ ␣ ␣ ␣ ␣ and sectioning locations␣ ␣ ␣ ␣ ␣ ␣

Laser Weld

Laser Weld

SECTIONING SHOULD NOT TAKE PLACE IN BLUE SHADED AREAS

Laser Weld

Laser Weld

50mm

30mm

5 Cut the door frame opening where sectioningis to be performed (Fig.␣ 1.4).Notice: Take care not to damage the innerpanels or reinforcements.

6 Locate, mark and drill out all factory welds.Note the number and location of welds forinstallation of the service part.

7 Remove the damaged area of door frameopening.Notice: Do not section within 100mm(4␣ inches) of laser welds (Fig.␣ 1.4).

D o o r F r a m e O p e n i n g


General Sectioning, continued— INSTALL OR CONNECT —

1 On the service part, mark cut lines at therecommended locations for sectioning.

2 Cut the panels to be sectioned.3 Cut 100mm (4 inch) sleeves from the unused

section of service part. If necessary, removethe flanges on both sides of this sleeve andmodify as necessary so that it will fit underthe sectioning joint.Notice: In any area damaged beyondrecognition, space plug weld holes every40mm (1-1/2 inches) apart.

4 On the service part, drill 8mm (5/16 inch)plug weld holes as necessary in the locationsnoted from the original part. Also, drill plugweld holes along the sectioning cuts on boththe service part and the remaining originalpanels. These should be locatedapproximately 25mm (1 inch) from the edgeof the cuts.

5 Prepare mating surfaces with a suitable weld-thru primer and slide the sleeves 50mm (2inches) beneath the remaining original

Fig.␣ 1.5 — Sectioning joint

panels. Position the service part, allowing itto overlap the exposed 50mm (2 inches) ofthe sleeves, leaving a gap one and one-halftimes the thickness of metal for welding.Check fit using three-dimensional measuring.Plug weld accordingly with frequentmeasurements to ensure proper fit.

6 Stitch weld along the sectioning joints(Fig.␣ 1.5). Make 25mm (1 inch) welds alongthe seam with 25mm (1 inch) gaps between.Then go back and complete the stitch weld.This will create a solid joint with minimal heatdistortion.

7 Clean and prepare welded surfaces.Important: Prior to refinishing, refer toGM P/N 4901 M-D Refinish Manual forrecommended products.

8 Apply approved anti-corrosion primer.9 Apply sealers and refinish as necessary. Do

not combine paint systems. Refer to paintmanufacturer’s recommendations.

10 Reinstall all related panels and components.

Door Frame Opening


Lower Front Hinge PillarSectioning— REMOVE OR DISCONNECT —

1 Remove all related panels and components.2 Visually inspect and restore as much of the

damage as possible to factory specifications.3 Remove sealers, sound deadeners and anti-

corrosion materials as necessary.4 Measure 80mm (3 1/8 inches) down from the

large wiring harness hole in the hinge pillarand mark a horizontal line. Cut the hingepillar along this line, taking care not todamage the inner panel (Fig.␣ 1.6).

5 Perform additional sectioning procedures asnecessary to remove damaged areas of thedoor frame opening.

6 Locate, mark and drill out all necessaryfactory welds. Note the number of welds forthe installation of the service section.

7 Remove the damaged section of the doorframe opening.

8 Cut and remove 30mm (1-3/16 inches) fromthe flanges on either side of the remainingsection of the original hinge pillar to create30mm (1-3/16 inch) tabs. Cut 5mm (3/16 inch)wide gaps in the bottom corners (Fig 1.7).

9 Step the tabs inward to allow the door frameopening service section to fit over theoriginal hinge pillar. Weld the tabs togetheralong the edges (Fig 1.8).Important: The metal of the hinge pillar isof a heavy gauge. However, the tabs canbe created using the appropriate tools.

Fig.␣ 1.8 — Weld corners

Fig.␣ 1.6 — Cut the hinge pillar

Fig.␣ 1.7 — Create tab on hinge

80mm

OriginalPanel

30mm

5mm

Weld Together

Door Frame Opening


Lower Front Hinge Pillar Sectioning,continued— INSTALL OR CONNECT —

1 On the service part, measure 50mm (2 inches)down from the large wiring harness hole in thehinge pillar and mark a horizontal line. Cut thehinge pillar along this line (Fig.␣ 1.9).

2 Perform additional sectioning procedures asnecessary to remove the unused areas of theservice part.Notice: In any area damaged beyondrecognition, space plug weld holes every40mm (1-1/2 inches) apart.

3 Drill 8mm (5/16 inch) plug weld holes asnecessary in the locations noted from theoriginal section. Also drill plug weld holesalong the hinge pillar sectioning cut of theservice part. These should be locatedapproximately 15mm (9/16 inch) from the edgeof the cut.

4 Prepare mating surfaces with a suitable weld-thru primer and position the service sectionover the stepped tab on the original hingepillar, allowing 30mm (1-3/16 inches) of overlap(Fig.␣ 1.10). Check fit using three-dimensionalmeasuring.

5 Plug weld accordingly with frequentmeasurements to ensure proper fit.

6 Stitch weld along the entire joint. Make25mm (1 inch) welds along the seam with25mm (1␣ inch) gaps between. Then go backand complete the stitch weld. This will createa solid joint with minimal heat distortion(Fig.␣ 1.11).

7 Complete all other welds and sectioningprocedures as necessary.

8 Clean and prepare welded surfaces.Important: Prior to refinishing, refer to GMP/N 4901 M-D Refinish Manual forrecommended products.

9 Apply approved anti-corrosion primer.10 Apply sealers and refinish as necessary. Do not

combine paint systems. Refer to paintmanufacturer’s recommendations.

11 Reinstall all related panels and components.

Fig.␣ 1.11 — Seamed joint

Fig.␣ 1.9 — Hinge pillar

Fig.␣ 1.10 — Stepped tab

50mm

ServicePanel

OriginalPanel

NewService Panel

OriginalPanel

30mmof overlap

Door Frame Opening


Body Side— REMOVE OR DISCONNECT —

1 Remove door from body. (Refer toappropriate service manual.)

2 Visually inspect and restore as much of thedamage as possible to factory specifications.

3 Lightly hand-sand existing hinge with 100 gritor finer sandpaper to locate the four weldsattaching hinge to the pillar (Fig.␣ 1.12).

4 Center punch each of the four weld marks onthe original hinge. It is critical to punch thecenter of the weld so that as much of the weldis removed during drilling as possible.Notice: Do not drill into the hinge pillar —drill through hinge ONLY (Fig.␣ 1.13). Ifnecessary, use a chisel to separate thehinge from the pillar.

Door Hinge Replacement

Fig.␣ 1.12 — Hand sand to locate welds on body hinge

Fig.␣ 1.13 — Drill hinge using rotabroach hole saw

13mm (1/2 inch)Rotabroach Bit

Hinge

Pillar

Hinge Reinforcement

Typical Mig WeldDrill through hinge only

5 At each punch location, drill through hingeONLY, using a 13mm (1/2 inch) rotabroachhole saw or equivalent. (Fig.␣ 1.13).

6 Remove all remaining weld material frompillar surface to ensure a flush fit of theservice hinge.


Body Side, continued — INSTALL OR CONNECT —

1 Repair any damage done to the pillar duringdrilling or removal.

2 Position the service template on the hingepillar using 3M’s Repositionable Adhesive(Part #6091), or equivalent.

3 Center punch each stud location on the hingepillar according to the template.

4 Drill 3mm (1/8 inch) pilot hole at each centerpunch location.

5 Using pilot hole as guide, drill a 11.5mm(29/64 inch) hole through hinge pillar at studlocations. Must be exact drill size (Fig.␣ 1.14).

6 Clean and prepare all bare metal surfaces.Important: Prior to refinishing, refer toGM P/N 4901 M-D Refinish Manual forrecommended products.

7 Apply approved anti-corrosion primer.8 Feed fish wire (such as GM part #15017229)

through hinge stud hole and out conduit holein the pillar (Fig.␣ 1.15).

9 Install stud (part #15017230) supplied withservice hinge into wire end and pull the studinto position. Draw the studs tight throughthe pillar using nuts (part #11516746)supplied. Remove each service nut.

10 Apply a full-bodied caulk to the entire hingemounting surface to ensure a proper seal.

11 Install hinge using nuts supplied, torque to 25N•m (20 FT. LB.) (Fig.␣ 1.16).

Fig.␣ 1.16 — Install door hinge body sideFig.␣ 1.14 — Drill hinge pillar to 11.5mm

Fig.␣ 1.15 — Feeding fish wire

Hinge

Nuts

Pillar

Hinge Reinforcement

Studs


12 Clean and prepare all surfaces as necessaryfor refinish.

13 Apply sealers and refinish as necessary. Donot combine paint systems. Refer to paintmanufacturer’s recommendations.

14 Install and align all related panels andcomponents.


Door Side— REMOVE OR DISCONNECT —

1 Remove door from body. (Refer toappropriate service manual.)

2 Visually inspect and restore as much of thedamage as possible to factory specifications.

3 Lightly hand-sand existing body hinge with100 grit or finer sandpaper to locate the fourwelds attaching hinge to door (Fig. 1.17).

4 Center punch each of the four weld marks onthe original hinge base. It is critical to punchthe center of the weld so that as much of theweld is removed during drilling as possible.Notice: Do NOT drill into the door —drill through hinge ONLY (Fig.␣ 1.18). Ifnecessary, use a chisel to separate thehinge from door.

Fig.␣ 1.17 — Hand-sand to locate welds on door hinge

Fig.␣ 1.18 — Rotabroach

13mm (1/2 inch)Rotabroach Bit

Hinge

Door

Hinge Reinforcement

Typical Mig WeldDrill through hinge only

5 At each punch location, drill through hingebase only using a 13mm (1/2 inch) rotabroachsaw, or equivalent. (Fig.␣ 1.18)

6 Remove all remaining weld from door surfaceto ensure a flush fit of service hinge.



Door Side, continued— INSTALL OR CONNECT —

1 Repair any damage done to door duringdrilling or removal.

2 Clean and prepare hinge and backing platemounting surfaces to ensure a flush fit of theservice hinge.

3 Position the service template on door using3M Repositionable Adhesive (part #6091), orequivalent.

4 Center punch each hole location on the dooraccording to the template.

5 Drill a 3mm (1/8 inch) pilot hole at eachcenter punch location.

6 Using pilot hole as guide, drill a 13mm (1/2inch) hole through door at pilot locations(Fig.␣ 1.19).

7 Clean and prepare all surfaces, as necessaryfor refinish.Important: Prior to refinishing, refer toGM P/N 4901 M-D Refinish Manual forrecommended products.

8 Apply approved anti-corrosion primer.9 Apply full-bodied caulk to the entire hinge

mounting surface to ensure a proper seal.10 Align the hinge and backing plate with the

holes in the door. Install bolts. Tighten boltsto 25 N•m (20 ft. lb.) (Fig.␣ 1.20).


12 Install and align all related panels andcomponents.

Fig.␣ 1.19 — Drill door to 13mm (1/2 inch)

Fig.␣ 1.20 — Install door hinge door side

Hinge

Door

Hinge Reinforcement

BackingPlate



Instrument Panel SupportThe Instrument Panel Support is a one-piececomponent comprised of a magnesium steeringcolumn support (Fig. 1.21), which holds theinstrumentation and steering column; a die-formed tube attaches to the passenger side andsupports the dashboard. This assembly functionsas a structural cross-vehicle beam, air-bagsupport, and instrument panel carrier, whichconsolidates many different steel and plasticcomponents.The magnesium instrument panel support isdesigned to deform and absorb energygenerated by a severe impact.

MagnesiumInstrument Panel Support

Fig 1.21 — Instrument panel support

Notice: Under no circumstance is themagnesium support to be repaired in anyway. If any of the following conditions arepresent after a collision, the magnesiumsupport must be replaced:

• Steering column capsules have released orcolumn has collapsed.

• The steel knee bolster brackets are bent.

• The parts which attach to the magnesiumsupport do not fit.

Kneebolster

Columncapsules

Magnesiumcolumn support

Die-formedtube


Steering ColumnIntermediate Shaft

Fig.␣ 1.23 — C2500 and K-series intermediate shaft

Fig.␣ 1.22— C1500 intermediate shaft

The redesigned steering column has aconvoluted style intermediate shaft (Figs.␣ 1.22and 1.23). The C1500 has one convoluted area,while all other models have two. Theseconvoluted areas must be inspected for damageafter every airbag deployment. Test thestraightness of the shaft at various locationsalong the convoluted area by placing a straightedge against the intermediate shaft. Theintermediate shaft must be replaced if bent ordamaged.


The redesigned frame of the C/K Pickupincorporates hydroformed technology, utilizinghigh-strength, low-alloy steel in the middle andrear sections; a replaceable, hydroformed,energy absorbing crush cap at the front of theframe (1500 series only); and a rear section that isreplaceable at factory seams as a one-pieceassembly.

Front Crush CapReplacement — C/K 1500— REMOVE OR DISCONNECT —

1 Remove all related panels and components.2 Visually inspect and restore all damage

rearward of crush cap. Restore to factoryspecifications using three-dimensionalmeasuring.Notice: If crush cap is bent or damaged inany way it must be replaced.

3 Remove core support mounting bracket(Fig.␣ 1.24).Notice: Use caution to not damage therail.

4 Locate brake line mounting hole on top ofrail. Measure forward 155mm (6-1/8 inches)This is your cut line. Scribe a line followingframe contour 360 degrees around frame railand forward of cross tube.

5 Remove crush cap at cut-line using diegrinder or appropriate tool.Notice: Use caution to not damage thecross tube (Fig.␣ 1.25).

6 Grind remaining weld off cross tube wheredamaged crush cap was removed (Fig.␣ 1.26).

Fig.␣ 1.24 — Remove core supportmounting bracket

Fig.␣ 1.25 — Remove damaged crash cap

Fig.␣ 1.26 — Remove remaining weld

155mm

Frame Service


Front Crush Cap Replacement, continued— INSTALL OR CONNECT —

1 Drill four plug weld holes (2 top, 2 bottom),15mm from cut line and 50mm (2 inches)apart on existing frame rail (Fig.␣ 1.27).

2 Prepare all bare metal surfaces with asuitable weld-thruh primer.

3 Install and position replacement crush capusing three-dimensional measuring.Notice: Retain a gap of one-and-one-halftimes the metal thickness at the butt jointwhen attaching the service part to thevehicle (Fig.␣ 1.28).

4 Tack weld part into position at initial plugweld holes.

5 Recheck service part for proper dimensions,then stitch weld along entire sectioning joint.Make 25mm (1 inch) welds along the seamwith 25mm (1 inch) gaps between. Go backand complete stitch weld. This will create asolid joint with minimal heat distortion.

6 Clean and prepare welded surfaces.Important: Prior to refinishing, refer toGM P/N 4901 M-D Refinish Manual forrecommended products.

7 Apply approved anti-corrosion primer.8 Position new core support mounting bracket

and weld in place according to specifieddimensions.


10 Replace related panels and components.Important: The replacement bumperbracket (Fig. 1.28) is a bolt-on componentthat must be ordered separately.

Fig.␣ 1.27 — Drill four plug weld holes

Fig.␣ 1.28 — Replacement crush cap

Frame Service

13mm

50mm

GAP = one and one-half timesthe thickness of the metal


Rear Module Replacement

Important: All steps are performed on bothrails for complete module replacement.

— REMOVE OR DISCONNECT —

1 Remove all related panels and components.2 Visually inspect and restore all damage

forward of rear module to factoryspecifications using three-dimensionalmeasuring.

3 Separate center and rear module at factorystitch weld with die grinder or appropriatetool (Fig.␣ 1.29).

4 Pry lower edge of cross tube bracket downto allow rear module to separate from centermodule (Fig.␣ 1.29).

5 Remove damaged rear module.

Important: It is necessary to monitor specifieddimensions by frequently performing three-dimensional measuring throughoutprocedures.

— INSTALL OR CONNECT —

1 Prepare all bare metal surfaces with asuitable weld-through primer.

2 Position and install replacement moduleusing three-dimensional measuring.

3 Restore bracket flange for flush fit to newservice part.

4 Tack weld into position. Recheck service partfor proper dimensions.

5 Stitch weld entire sectioning joint.6 Clean and prepare welded surfaces.

Important: Prior to refinishing, refer toGM P/N 4901 M-D Refinish Manual forrecommended products.

7 Apply approved anti-corrosion primer.8 Apply sealers and refinish as necessary. Do

not combine paint systems. Refer to paintmanufacturer’s recommendations.

9 Install all related panels and components.

Fig. 1.29 — Rear module

Factory joint

Cross tubebracket

Bend flangedown

FRT

Frame Service


Body Dimensions

L: 444W: 770H: 1270

C

L: 387W: 794H: 1274

D

AL: 405W: 794H: 1273

L: 495W: 770H: 1266

B

L: 80W: 860H: 1022

E

L: 1086W: 860H: 569

G

L: 1715W: 868H: 892

H

L: 1735W: 889H: 972

I

L: 117W: 868H: 930

F

E

L: 117W: 868H: 930

F

L: 1063W: 876H: 1004

J

L: 80W: 860

H: 1022


1277

397

1579

1486 1486

412

L: 1208W: 638H: 1774

BACK OF CAB (REAR VIEW)

N

L: 1253W: 790H: 1387

M

Body Dimensions

1357

690

1455

1566 1566

L: 322W: 679H: 1758

L

L: 213W: 728H: 1324

K

WINDSHIELD OPENING


Body Dimensions

Cab Hole Identification

Letter Feature Usage

A 12mm hole Cowl drain vent retainer hole

B 11mm hole Fender bracke attachment hole

C 12mm x 8mm slot Cowl drain vent retainer hole

D 11mm x 14mm slot Fender brack attachment hole

E 8mm weld nut Check strap mount hole

F 54mm hole Front door wiring harness hole

G 8mm weld nut Access door striker forward mount hole

H 8mm weld nut Access door check strap mount hole

I 34mm hole Access door wiring harness hole

J 8mm weld nut Front door striker upper mount hole

K Corner of windshield pillar flange

L Front roof flange corner

M Lower corner backglass flange

N Rear roof flange corner


C1500 Silverado and Sierra Extended Cab Long Box

Frame Dimensions

0

L:

999

W:

685

H:

481

M

L:

469

W:

553

H:

450

XL

:11

76W

: 4

12H

: 5

66

WL

:14

82W

: 4

39H

: 5

87

V

L:

1456

W:

370

H:

732

RL

:11

50W

: 3

87H

: 7

00

S

L:

793

W:

451

H

: 6

86

T

L:

489

W:

450

H:

642

U

L:

179

5W

: 6

85H

: 6

16

L

L:

1794

W:

553

H:

460

Y

L:

2502

W:

659

H:

507

ZL

:27

26W

: 5

53H

: 6

75

AA

L:

3421

W:

531

H:

720

BB

L:

4106

W:

659

H:

580

CC

L:

1971

W:

0

H:

755

K

L:

2458

W:

522

H:

609

F

L:

3365

W:

499

H:

659

G

L:

4043

W:

496

H:

649

H

L:

4368

W:

496

H:

773

I

L:

3958

W:

0

H:

747

J

L:

2012

W:

600

H:

772

E

L:

0W

: 5

23H

:38

2

D

L:

99W

: 6

70H

: 4

97

C

L:

973

W:

0

H:

392

N

L:

1179

W:

385

H:

487

O

L:

1441

W:

387

H:

565

P

L:

1458

W:

275

H:

594

QL:

1327

W:

387

H:

565

A

L:

1311

W:

590

H:

659

B


Frame Dimensions

C1500 Silverado and Sierra Extended Cab Long BoxFrame Hole Identification Chart


A 32mm Hole Bottom surface of rail

B 41mm x 39mm Hole Body mount bracket

C 41mm x 39mm Hole Body mount bracket

D 17mm Hole Bottom surface of rail

E 17.5mm Hole (Front) Box mount bracket

F 20mm x 35mm Hole Bottom surface of rail

G 11mm Hole Bottom surface of rail

H 15.5mm Hole Bottom surface of rail

I 18mm x 20mm Slot Top surface of rail

J 25mm x 40mm Slot Bottom surface of spare wheel bracket

K 10mm Hole Bottom surface of cross bar

L 41mm x 39mm Hole Body mount bracket

M 41mm x 39mm Hole Body mount bracket

N 18mm x 22mm Bottom surface of crossmember (engine)

O 9mm Hole Top surface of rail

P 13mm Hole Bottom surface tow hook attachment

Q 13mm x 27mm Slot Bottom slot bumper attachment

R 16mm Weld Nut Bumper attachment

S 8mm Hole Top of rail

T 15mm x 34mm Slot Front upper control arm attachment bracket

U 15mm x 34mm Slot Rear upper control arm attachment bracket

V 13mm Hole Side of rail tow hook attachment

W 18mm x 35mm Slot Side of rail shipment slot

X 25mm Hole Side of rail

Y 14mm Hole Side of rail

Z 18mm Hole Front shackle mounting bracket

AA 25mm x 40mm Slot Side of rail

BB 25mm x 40mm Slot Side of rail

CC 15mm Hole Rear shackle mounting bracket


Frame Dimensions

C2500 Silverado and Sierra Extended Cab Long Box0

L:

2726

W:

552

H:

674

Z

L:

2496

W:

660

H:

495

Y

L:

1794

W:

553

H:

460

XL

:46

9W

:55

3H

:45

0

W

L:

1142

W:

443

H:

547

V

L:

1408

W:

454

H:

524

U

L:

1456

W:

370

H:

735

R

L:

840

W:

428

H:

704

SL

:44

9W

:40

1H

:67

2

T

L:

1117

W:

403

H:

462

OL

:13

27W

:41

1H

:47

0

P

L:

1459

W:

275

H:

592

QL

:74

2W

:0

H:

370

N

L:

99W

:67

0H

:50

0

B

L:

0W

:55

3H

:37

0

C

L:

2012

W:

600

H:

775

D

L:

2458

W:

522

H:

562

E

L:

1968

W:

0H

:69

6

J

L:

999

W:

685

H:

484

LL

:17

93W

:68

6H

:61

6

K

L:

3357

W:

500

H:

621

FL

:40

43W

:49

6H

:64

9

G

L:

4368

W:

496

H:

773

H

L:

3957

W:

0H

:75

0

I

L:

463

W:

242

H:

353

M

L:

1319

W:

590

H:

593

A

L:

3421

W:

531

H:

720

AA

L:

4106

W:

660

H:

560

BB


Frame Dimensions

C2500 Silverado and Sierra Extended Cab Long BoxFrame Hole Identification Chart


A 39mm x 41mm Hole Body mount bracket

B 39mm x 41mm Hole Body mount bracket

C 17mm Hole Bottom surface of rail

D 17.5mm Hole (Front) Box mount bracket

E 39mm x 24mm Slot Bottom surface of rail

F 11mm Hole Bottom surface of rail

G 15.5mm Hole Bottom surface of rail

H 20mm x 18mm Slot Top surface of rail

I 40mm x 25mm Slot Bottom surface of spare wheel bracket

J 10mm Hole Bottom surface of crossmember

K 41mm x 39mm Hole Bottom surface of cross bar

L 41mm x 39mm Hole Body mount bracket

M 13.5mm Hole Body mount bracket

N 40mm x 25mm Slot Bottom surface of crossmember (engine)

O 9mm Hole Top surface of rail

P 32mm Hole Bottom surface of rail

Q 13mm x 27mm Slot Bottom of bumper mount bracket

R 16.5mm Hole Top of bumper mount bracket

S 34mm x 15mm Slot Front upper control arm attachment bracket

T 34mm x 15mm Slot Rear upper control arm attachment bracket

U 13mm Hole Side of rail two hook attachment

V 35mm x 18mm Slot Side of rail shipment slot

W 25mm Hole Side of rail

X 14mm Hole Side of rail

Y 18mm Hole Front shackle mounting bracket

Z 40mm x 25mm Slot Side of rail

AA 40mm x 25mm Slot Side of rail

BB 15mm Hole Rear shackle mounting bracket


Fastener Tightening Specifications

Appendix

Application N.m Lb Ft Lb In

Outer Tie Rod to Knuckle 45 33

Idler Arm to Frame Bolt 70 52

Outer Tie Rod Adjuster Sleeve 68 50

Pitman Arm Retaining Nut 250 184

Idler Arm to Frame Bolt 70 52

Relay Rod to Idler and Pitman Arm Nut 63 46

Hose Fittings to Steering Gear 28 21

Pinch Bolt to Intermediate Shaft 62 46

Steering Gear Retaining Bolts 95 70

Axle Shaft Nut (K Models) 200 148

Brake Hose Bracket Bolt 9 — 80

Brake Hose Clamp Bolts 12 — 106

Hub and Bearing Assembly to Steering — —

Knuckle Bolts 180 133

Lower Ball Joint to Steering Knuckle Nut 72 53

Lower Control Arm Bumper (C Models) 32 23

Lower Control Arm to Frame Nuts & Bolts 165 121

Outer Tie Rod Nut 62 46

Shock Absorber to Control Arm Nuts (K Models) 90 66

Shock Absorber Upper Nut 20 15

Shock Absorber to Control Arm Bolts (C Models) 25 19

Stabilizer Bar Bracket to Frame Nuts & Bolts 33 24

Stabilizer Link Nuts 20 15

Torsion Bar Support Link Nuts (25 Series K Models) 95 70

Torsion Bar Support Mounting Nuts (15 Series — —

K Models) 95 70

Upper Ball Joint Nuts (C Models) 24 18

Upper Ball Joint to Steering Knuckle Nut 50 37

Upper Control Arm to Frame Nuts & Bolts 125 92

Leaf Spring to Bracket Nuts 125 92

Leaf Spring to Shackle Nuts 95 70

Shackle to Bracket Nuts 95 70

Shock Absorber Lower Nuts 95 70

Shock Absorber Upper Nuts 95 70

U Bolt Nuts (Gas Engine) 80 59

U Bolt Nuts (Diesel) 120 89

Front Bumper to Frame Bracket Bolt 85 63

Front Bumper Bracket to Brace Bolt 55 41

Rear Bumper Bracket to Frame Side Bolt 50 37

Rear Bumper Bracket to Frame Nut 90 66

Rear Bumper Bracket to Frame Lower Bolt 125 92

Weight Distribution Hitch to Frame Nuts & Bolts 125 92

Seat Riser to Floor Stud Nuts 55 41

Rear Seat Track to Floor Nuts 55 41

Seat Belt Attachments 53 39

Seat Belt Anchors 53 39

Seat Back to Recliner Bolts 53 39

Body Repair Manual 1463KB

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