Chevrolet Silverado / GMC Sierra. Manual - part 1299

Fig. 111: Plug Welding Pickup Box Front Panel 
Courtesy of GENERAL MOTORS CORP. 

4. Plug weld into position.  

5. Clean and prepare all welded surfaces.  

6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion 

Treatment and Repair .  

7. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems .  

8. Install the pickup box assembly. Refer to Pickup Box Replacement .  

PICKUP BOX REPLACEMENT - SIDE 

Description 

This procedure shows illustrations for the 6.6L box. The 5.8, 8.0, and dually pickup boxes are similar. This 
procedure may be used for all pickup box sizes. 

Removal Procedure 

CAUTION: Refer to Approved Equipment for Collision Repair Caution .

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:21:00 PM

Page 122 

© 2005 Mitchell Repair Information Company, LLC. 

1. Remove the box assembly. Refer to Pickup Box Replacement .  

2. Remove all related panels and components.  

3. Repair as much of the damage as possible, according to factory specifications.  

4. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. 

Refer to Anti-Corrosion Treatment and Repair . 

Fig. 112: Drilling Out Spot Welds 
Courtesy of GENERAL MOTORS CORP. 

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

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:21:00 PM

Page 123 

© 2005 Mitchell Repair Information Company, LLC. 

Fig. 113: Drilling Out Spot Welds On Front Bed Panel 
Courtesy of GENERAL MOTORS CORP. 

6. Locate and drill out the spot welds along the front bed panel. 

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:21:00 PM

Page 124 

© 2005 Mitchell Repair Information Company, LLC. 

Fig. 114: View Of Cross Sill 
Courtesy of GENERAL MOTORS CORP. 

7. Use a heat gun or a chisel to separate the stake pocket reinforcement from the cross sill (1). 

IMPORTANT: Structural adhesive is used to bond the front stake pocket reinforcement 

to the mating cross sill.

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:21:01 PM

Page 125 

© 2005 Mitchell Repair Information Company, LLC.