torn bed sheet metal??????
07-19-2003, 03:45 AM
#1
TECH Fanatic
Thread Starter
torn bed sheet metal??????
should i just go to a body shop and get this fixed? or go to the dealer to get it fixed? how much do u think this i gunna cost me? i need to install my tonneau cover back on.
Pickup Box Sheet Metal Fracture/Damage with Aftermarket Accessories Installed (Repair Pickup Box Damage and Install Pickup Box Reinforcements) #01-08-66-014A - (08/09/2002)
Pickup Box Sheet Metal Fracture/Damage with Aftermarket Accessories Installed (Repair Pickup Box Fracture/Damage and Install Pickup Box Reinforcements)
1999-2003 Chevrolet Silverado (New Body Style)
1999-2003 GMC Sierra (New Body Style)
with Steel Fleetside Pickup Box (RPO E63)
Except Dual Rear Wheel (RPO R05), Stepside (RPO E62) and Inner Composite (RPO E37) Pickup Boxes
This bulletin is being revised to add the 2003 model year and VIN breakpoint information. Please discard Corporate Bulletin Number 01-08-66-014 (Section 08 -- Body and Accessories).
Built Prior to the following VIN Breakpoints:
Plant
VIN Breakpoint
Fort Wayne, IN
3Z115302
Flint, MI
3F102974
Pontiac, MI
3E115871
Oshawa, ONT
31108937
Important
Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval.
Condition
Some customers may comment about pickup box sheet metal fractures/damage when using aftermarket accessories such as tool boxes, window barrier and ladder racks.
The following illustrations are typical examples of the types of fractures/damage that may occur.
FIGURE Pickup Box Perforation (Left Front of Box)(c)
FIGURE Pickup Box Perforation (Inner Side - Rear)(c)
FIGURE Pickup Box Perforation (Outer Front of Box with Pickup Box Removed)(c)
Correction
Repair the damaged pickup box using the following procedure. When repairing any damage to the front of the pickup box, it may be necessary to remove the pickup box from the frame.
Drill a 6 mm (0.23 in) hole in the extreme end of the crack.
Prepare inner crack for welding.
Important
Do not use oxyacetylene welding equipment. MIG WELD ONLY.
Weld the crack using the appropriate welding technique.
Clean and prepare all of the welding surfaces.
Return surface contour to its original contour.
Important
Prior to refinishing, refer to publication GM4901M-D-2002 (English) or GM4901M-D-F2002 (French) GM Approved Refinish Materials for recommended products. Do not combine the paint systems. Refer to the paint manufacturer's recommendations.
Refinish as necessary.
Apply an approved anti-corrosion material to all of the bare metal surfaces.
After completion of any repairs due to the use of aftermarket accessories, install new pickup box reinforcements using the following procedure and the applicable part numbers listed below.
Pickup Box Reinforcement Installation
Important
The reinforcements must be installed before adding a toolbox or ladder rack system. After the reinforcements have been installed, follow the instructions supplied with the toolbox/ladder rack system for installation onto the pickup box.
Use the following service procedure to install the reinforcements. Use the applicable reinforcement kit part number listed below.
Cross Toolbox and Rear Window Barrier Applications - Front Reinforcement Installation
Important
The horizontal surfaces of the reinforcements must be flush to the horizontal surface of the pickup box top rail. Use a clamping tool when positioning the reinforcements onto the top rail to ensure flushness to the outer panel.
Place the front L-shaped reinforcements into position on the front top of the pickup box. For vehicles equipped with an over the rail bedliner, the bedliner should be removed with the aid of an assistant prior to installing these reinforcements.
Mark the holes necessary for drilling.
Remove the front reinforcements.
Important
Use a block of wood and/or a drill stop in order to protect the back of the cab while drilling.
Drill two 13.5 mm (0.54 in) holes per side into the box section of the front panel.
Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel.
Apply anti-corrosion material to the drilled holes as necessary using the information found in the applicable Service Manual and GM Refinish Material Booklet 4901M-D-2002 (English) or 4901M-D-F2002 (French).
Place the front reinforcements back onto the box, lining up the drilled holes.
Install the large shoulder (M8) bolts into the reinforcement and front panel (total of 4) and the small (M6) bolts into the reinforcement and side outer panel (total of 6) with the nuts. Tighten
Tighten the M8 bolts to 25 N·m (18 lb ft).
Tighten the M6 bolts to 9 N·m (79 lb in).
Remove all metal shavings from the pickup box after installation.
Install the bedliner if equipped with the aid of an assistant. The bedliner may need to be trimmed in order to obtain the necessary clearance for the reinforcements.
Ladder Rack and/or Side Tool Box Applications - Reinforcement Kit Installation
Install the LH and RH front L-shaped reinforcements using the procedure above.
Remove the LH and RH rear taillamp assemblies. This is necessary to gain access to install the rearmost bolt of the rear reinforcement.
Place the LH and RH rear reinforcements into position on the pickup box.
Mark the holes necessary for drilling and remove the reinforcements.
Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel.
Apply anti-corrosion material to the drilled holes as necessary. Refer to step 6 under Front Reinforcement Installation procedure.
Place the rear reinforcements back onto the pickup box.
Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten
Tighten the bolts to 9 N·m (79 lb in).
Install the LH and RH rear taillamp assemblies.
Place the LH and RH center reinforcement into position on the pickup box.
On the 2.4 m (8 ft) long pickup box models, this center reinforcement fits over the existing center stake hole.
On the 2 m (6.5 ft) short box models, these center reinforcements are recommended to be installed. The reinforcements should be centered between the front and rear reinforcements on the pickup box.
Mark the holes necessary for drilling and remove the brackets.
Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel.
Touch-up the drilled holes as necessary. Refer to step 6 under the Front Reinforcement Installation procedure.
Place the center reinforcements back onto the pickup box.
Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten
Tighten the bolts to 9 N·m (79 lb in).
Remove any metal shavings from the pickup box after installation.
*Maximum Equipment Weight Capacities (Equipment and Cargo)
Ladder Rack and Cargo - 364 kg (800 lb)
Cross Toolbox and Cargo - 182 kg (400 lb)
Side Tool boxes and Cargo - 159 kg (350 lb) (per side)
*The combined weight for all rail-mounted equipment should not exceed 545 kg (1, 200 lb).
Parts Information
P/N 15068208 contains the reinforcements necessary to install ladder rack systems and/or side-mounted toolboxes.
P/N 15068209 contains the reinforcements for cross toolbox and/or rear window barrier applications only.
Part Number
Description
15068208
Reinforcement Kit - Pickup Box Otr S/PNL
Includes Frt, Ctr, and Rr S/PNL Reinforcements (LH and RH) w/Bolts and Nuts
15068209
Reinforcement Kit - Pickup Box Otr S/PNL
Includes Frt S/PNL Reinforcements (LH and RH) w/Bolts and Nuts
Parts are currently available from GMSPO.
Pickup Box Sheet Metal Fracture/Damage with Aftermarket Accessories Installed (Repair Pickup Box Damage and Install Pickup Box Reinforcements) #01-08-66-014A - (08/09/2002)
Pickup Box Sheet Metal Fracture/Damage with Aftermarket Accessories Installed (Repair Pickup Box Fracture/Damage and Install Pickup Box Reinforcements)
1999-2003 Chevrolet Silverado (New Body Style)
1999-2003 GMC Sierra (New Body Style)
with Steel Fleetside Pickup Box (RPO E63)
Except Dual Rear Wheel (RPO R05), Stepside (RPO E62) and Inner Composite (RPO E37) Pickup Boxes
This bulletin is being revised to add the 2003 model year and VIN breakpoint information. Please discard Corporate Bulletin Number 01-08-66-014 (Section 08 -- Body and Accessories).
Built Prior to the following VIN Breakpoints:
Plant
VIN Breakpoint
Fort Wayne, IN
3Z115302
Flint, MI
3F102974
Pontiac, MI
3E115871
Oshawa, ONT
31108937
Important
Implementation of this Service Bulletin by "GM of Canada" dealers requires prior District Service Manager approval.
Condition
Some customers may comment about pickup box sheet metal fractures/damage when using aftermarket accessories such as tool boxes, window barrier and ladder racks.
The following illustrations are typical examples of the types of fractures/damage that may occur.
FIGURE Pickup Box Perforation (Left Front of Box)(c)
FIGURE Pickup Box Perforation (Inner Side - Rear)(c)
FIGURE Pickup Box Perforation (Outer Front of Box with Pickup Box Removed)(c)
Correction
Repair the damaged pickup box using the following procedure. When repairing any damage to the front of the pickup box, it may be necessary to remove the pickup box from the frame.
Drill a 6 mm (0.23 in) hole in the extreme end of the crack.
Prepare inner crack for welding.
Important
Do not use oxyacetylene welding equipment. MIG WELD ONLY.
Weld the crack using the appropriate welding technique.
Clean and prepare all of the welding surfaces.
Return surface contour to its original contour.
Important
Prior to refinishing, refer to publication GM4901M-D-2002 (English) or GM4901M-D-F2002 (French) GM Approved Refinish Materials for recommended products. Do not combine the paint systems. Refer to the paint manufacturer's recommendations.
Refinish as necessary.
Apply an approved anti-corrosion material to all of the bare metal surfaces.
After completion of any repairs due to the use of aftermarket accessories, install new pickup box reinforcements using the following procedure and the applicable part numbers listed below.
Pickup Box Reinforcement Installation
Important
The reinforcements must be installed before adding a toolbox or ladder rack system. After the reinforcements have been installed, follow the instructions supplied with the toolbox/ladder rack system for installation onto the pickup box.
Use the following service procedure to install the reinforcements. Use the applicable reinforcement kit part number listed below.
Cross Toolbox and Rear Window Barrier Applications - Front Reinforcement Installation
Important
The horizontal surfaces of the reinforcements must be flush to the horizontal surface of the pickup box top rail. Use a clamping tool when positioning the reinforcements onto the top rail to ensure flushness to the outer panel.
Place the front L-shaped reinforcements into position on the front top of the pickup box. For vehicles equipped with an over the rail bedliner, the bedliner should be removed with the aid of an assistant prior to installing these reinforcements.
Mark the holes necessary for drilling.
Remove the front reinforcements.
Important
Use a block of wood and/or a drill stop in order to protect the back of the cab while drilling.
Drill two 13.5 mm (0.54 in) holes per side into the box section of the front panel.
Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel.
Apply anti-corrosion material to the drilled holes as necessary using the information found in the applicable Service Manual and GM Refinish Material Booklet 4901M-D-2002 (English) or 4901M-D-F2002 (French).
Place the front reinforcements back onto the box, lining up the drilled holes.
Install the large shoulder (M8) bolts into the reinforcement and front panel (total of 4) and the small (M6) bolts into the reinforcement and side outer panel (total of 6) with the nuts. Tighten
Tighten the M8 bolts to 25 N·m (18 lb ft).
Tighten the M6 bolts to 9 N·m (79 lb in).
Remove all metal shavings from the pickup box after installation.
Install the bedliner if equipped with the aid of an assistant. The bedliner may need to be trimmed in order to obtain the necessary clearance for the reinforcements.
Ladder Rack and/or Side Tool Box Applications - Reinforcement Kit Installation
Install the LH and RH front L-shaped reinforcements using the procedure above.
Remove the LH and RH rear taillamp assemblies. This is necessary to gain access to install the rearmost bolt of the rear reinforcement.
Place the LH and RH rear reinforcements into position on the pickup box.
Mark the holes necessary for drilling and remove the reinforcements.
Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel.
Apply anti-corrosion material to the drilled holes as necessary. Refer to step 6 under Front Reinforcement Installation procedure.
Place the rear reinforcements back onto the pickup box.
Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten
Tighten the bolts to 9 N·m (79 lb in).
Install the LH and RH rear taillamp assemblies.
Place the LH and RH center reinforcement into position on the pickup box.
On the 2.4 m (8 ft) long pickup box models, this center reinforcement fits over the existing center stake hole.
On the 2 m (6.5 ft) short box models, these center reinforcements are recommended to be installed. The reinforcements should be centered between the front and rear reinforcements on the pickup box.
Mark the holes necessary for drilling and remove the brackets.
Drill 7.5 mm (0.30 in) holes into the weld flange of the side outer panel.
Touch-up the drilled holes as necessary. Refer to step 6 under the Front Reinforcement Installation procedure.
Place the center reinforcements back onto the pickup box.
Install the M6 bolts through the reinforcement and side panel with the nuts. Tighten
Tighten the bolts to 9 N·m (79 lb in).
Remove any metal shavings from the pickup box after installation.
*Maximum Equipment Weight Capacities (Equipment and Cargo)
Ladder Rack and Cargo - 364 kg (800 lb)
Cross Toolbox and Cargo - 182 kg (400 lb)
Side Tool boxes and Cargo - 159 kg (350 lb) (per side)
*The combined weight for all rail-mounted equipment should not exceed 545 kg (1, 200 lb).
Parts Information
P/N 15068208 contains the reinforcements necessary to install ladder rack systems and/or side-mounted toolboxes.
P/N 15068209 contains the reinforcements for cross toolbox and/or rear window barrier applications only.
Part Number
Description
15068208
Reinforcement Kit - Pickup Box Otr S/PNL
Includes Frt, Ctr, and Rr S/PNL Reinforcements (LH and RH) w/Bolts and Nuts
15068209
Reinforcement Kit - Pickup Box Otr S/PNL
Includes Frt S/PNL Reinforcements (LH and RH) w/Bolts and Nuts
Parts are currently available from GMSPO.
07-19-2003, 03:12 PM
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Re: torn bed sheet metal??????
Shiat, if it's still under warranty, I'd be like, "Fix that **** for free...and now!" 
If it isn't under warranty and won't fix it for free, raise hell until they do
If it isn't under warranty and won't fix it for free, raise hell until they do
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