Chevrolet Silverado / GMC Sierra. Manual - part 1300

Fig. 115: View Of Damaged Side Panel 
Courtesy of GENERAL MOTORS CORP. 

8. Remove the side panel.  

Installation Procedure 

1. Drill 8 mm (5/16 in) plug weld holes in the service part as noted.  

2. Prepare all mating surfaces as necessary.  

3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion 

Treatment and Repair . 

4. Grind the surface of the pickup box cross sill and the front stake pocket reinforcement mating flanges to 

bare steel. 

IMPORTANT: Before you begin the repair, refer to Metal Panel Bonding for proper 

adhesive preparation and general information.

 

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

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Fig. 116: Applying Metal Panel Bonding Adhesive 
Courtesy of GENERAL MOTORS CORP. 

5. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive to both of the mating surfaces.  

6. using a small acid brush, spread a coat of adhesive to both of the mating surfaces. Cover all of the bare 

metal to ensure corrosion protection.  

7. Apply three 9-13 mm (3/8-1/2 in) beads of metal panel bonding adhesive as shown. 

IMPORTANT: Do not allow the adhesive to cure prior to installing the service side panel.

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:21:01 PM

Page 127 

© 2005 Mitchell Repair Information Company, LLC. 

Fig. 117: View Of Side Panel 
Courtesy of GENERAL MOTORS CORP. 

8. Position the service side panel to the bed assembly. 

IMPORTANT: Do NOT pull the panels apart after you have joined the panels together. 

Slide the panels against each other to realign the panels.

 

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 128 

© 2005 Mitchell Repair Information Company, LLC. 

Fig. 118: Plug Welding New Side Panel 
Courtesy of GENERAL MOTORS CORP. 

9. Plug weld as necessary  

10. Clean and prepare all welded surfaces.  

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

Treatment and Repair .  

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

13. Install all related panels and components.  

14. Install the box assembly. Refer to Pickup Box Replacement .  

PICKUP BOX OUTER SIDE PANEL REPLACEMENT (BOND-ON) 

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 2:21:01 PM

Page 129 

© 2005 Mitchell Repair Information Company, LLC.