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Tahoe / Yukon Service Manual

Body Front Structure Parts Replacement

Materials Structure Adhesive Metal Panel Bonding Structure Rivet [SR1 18x] Fastener Specifications Structure Rivet [SR2 4x] Fastener Specifications Removal Procedure

Body Front Structure Parts Replacement — figure 1
Body Front Structure Parts Replacement — figure 1
  1. Disable the SIR system. SIR Disabling and Enabling.
  2. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
  3. Remove all related panels and components.
  4. Remove both front fender bracket. Front Fender Bracket Replacement
  5. Remove both front fender rear bracket. Front Fender Rear Bracket Replacement
  6. Remove the sealers and anti-corrosion materials from the repair area as necessary. Anti-Corrosion Treatment and Repair
Body Front Structure Parts Replacement — figure 2
Body Front Structure Parts Replacement — figure 2

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Body Front Structure Parts Replacement — figure 3
Body Front Structure Parts Replacement — figure 3
Body Front Structure Parts Replacement — figure 4
Body Front Structure Parts Replacement — figure 4
  1. Remove front end section (1) from the vehicle.
Body Front Structure Parts Replacement — figure 5
Body Front Structure Parts Replacement — figure 5
  1. Remove front compartment side rail bracket (1) – rear right. Front Compartment Side Rail Bracket Replacement - Rear
  2. Remove front compartment side rail bracket (2) – rear left. Resistance Spot Welded Full Panel Replacement
Body Front Structure Parts Replacement — figure 6
Body Front Structure Parts Replacement — figure 6
  1. Remove all spot welds (1). [36x]
Body Front Structure Parts Replacement — figure 7
Body Front Structure Parts Replacement — figure 7
  1. Apply heat to shaded area (1) to release adhesive.
Body Front Structure Parts Replacement — figure 8
Body Front Structure Parts Replacement — figure 8
  1. Remove outer rail sections (1) from the vehicle.
Body Front Structure Parts Replacement — figure 9
Body Front Structure Parts Replacement — figure 9
  1. Remove all spot welds (1). [4x]
Body Front Structure Parts Replacement — figure 10
Body Front Structure Parts Replacement — figure 10
  1. Remove all spot welds (1). [5x]
Body Front Structure Parts Replacement — figure 11
Body Front Structure Parts Replacement — figure 11
  1. Apply heat to shaded area (1) to release adhesive.
Body Front Structure Parts Replacement — figure 12
Body Front Structure Parts Replacement — figure 12
  1. Remove outer rail reinforcements (1) from the vehicle.
Body Front Structure Parts Replacement — figure 13
Body Front Structure Parts Replacement — figure 13
  1. Cut the inner side rail at the marked location (1).
Body Front Structure Parts Replacement — figure 14
Body Front Structure Parts Replacement — figure 14

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Body Front Structure Parts Replacement — figure 15
Body Front Structure Parts Replacement — figure 15
  1. Remove inner rail sections (1) from the vehicle.
  2. Remove remaining adhesive from vehicle. Installation Procedure
Body Front Structure Parts Replacement — figure 16
Body Front Structure Parts Replacement — figure 16

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Body Front Structure Parts Replacement — figure 17
Body Front Structure Parts Replacement — figure 17
  1. Position front end (1) to vehicle using 3-dimensional measuring equipment and clamp into place.
  2. Temporarily install radiator support body mounting bolts to ensure proper alignment.
Body Front Structure Parts Replacement — figure 18
Body Front Structure Parts Replacement — figure 18
  1. Drill 6.7 mm (17/64”) hole (1) on outer side rail and vehicle for rivet installation. [5x]
Body Front Structure Parts Replacement — figure 19
Body Front Structure Parts Replacement — figure 19

  1. Drill 6.7 mm (17/64”) hole (1) on inner side rail and vehicle for rivet installation. [6x]

  2. Remove the front end (1) and radiator support body mounting bolts from the vehicle.

Body Front Structure Parts Replacement — figure 20
Body Front Structure Parts Replacement — figure 20
  1. Position rear rail bracket (2) to front end (1) using 3-dimensional measuring equipment and clamp into place.
Body Front Structure Parts Replacement — figure 21
Body Front Structure Parts Replacement — figure 21
  1. Rear rail bracket (1) will be located 24 mm (0.9”) from inner side rail sectioning mark (2).
Body Front Structure Parts Replacement — figure 22
Body Front Structure Parts Replacement — figure 22
  1. Drill 6.7 mm (17/64”) hole (1) on rear rail bracket and vehicle for rivet installation. [1x]
Body Front Structure Parts Replacement — figure 23
Body Front Structure Parts Replacement — figure 23
  1. Drill 6.7 mm (17/64”) hole (1) on rear rail bracket and vehicle for rivet installation. [1x]
Body Front Structure Parts Replacement — figure 24
Body Front Structure Parts Replacement — figure 24
  1. Remove the rear rail bracket (2) from the front end (1).
Body Front Structure Parts Replacement — figure 25
Body Front Structure Parts Replacement — figure 25
  1. Drill 8 mm (5/16”) plug weld holes (1). [4x]
  2. Prepare all joining surfaces for welding as necessary.
  3. Apply GM-approved weld-thru coating or equivalent to all welding surfaces. Anti-Corrosion Treatment and Repair
Body Front Structure Parts Replacement — figure 26
Body Front Structure Parts Replacement — figure 26
  1. Clean and prepare side rails and vehicle for adhesive according to adhesive manufacturer’s recommendations. Metal Panel Bonding
  2. Apply structural adhesive (1) on the mating surfaces of side rails and vehicle according to adhesive manufacturer’s recommendations. Metal Panel Bonding
Body Front Structure Parts Replacement — figure 27
Body Front Structure Parts Replacement — figure 27
  1. Apply structural adhesive (1) on the mating surfaces of side rails and vehicle according to adhesive manufacturer’s recommendations. Metal Panel Bonding
Body Front Structure Parts Replacement — figure 28
Body Front Structure Parts Replacement — figure 28

  1. Apply structural adhesive (1) on the mating surfaces of side rails and rear rail bracket according to adhesive manufacturer’s recommendations. Metal Panel Bonding

  2. Install front end (1) to vehicle and clamp into place.

  3. Install radiator support body mounting bolts to ensure proper alignment. Body Upgrade Mount Replacement

Body Front Structure Parts Replacement — figure 29
Body Front Structure Parts Replacement — figure 29
  1. Install rivets (1) in outer side rail. [SR1 4x] Fastener Specifications
Body Front Structure Parts Replacement — figure 30
Body Front Structure Parts Replacement — figure 30
  1. Install rivets (1) in inner side rail. [SR1 6x] Fastener Specifications
Body Front Structure Parts Replacement — figure 31
Body Front Structure Parts Replacement — figure 31
  1. Install rear rail bracket (1) to vehicle and clamp into place.
Body Front Structure Parts Replacement — figure 32
Body Front Structure Parts Replacement — figure 32
  1. Install rivets (1) in inner side rail. [SR1 4x] Fastener Specifications
  2. Install rivets (2) in inner side rail. [SR2 2x] Fastener Specifications
Body Front Structure Parts Replacement — figure 33
Body Front Structure Parts Replacement — figure 33
  1. Install rivet (1) in outer side rail. [SR2 1x] Fastener Specifications
Body Front Structure Parts Replacement — figure 34
Body Front Structure Parts Replacement — figure 34

Click Image For Video

Body Front Structure Parts Replacement — figure 35
Body Front Structure Parts Replacement — figure 35
  1. Install spot welds (1). [20x]
Body Front Structure Parts Replacement — figure 36
Body Front Structure Parts Replacement — figure 36
  1. Install spot welds (1). [17x]
Body Front Structure Parts Replacement — figure 37
Body Front Structure Parts Replacement — figure 37
  1. Install MIG/MAG welds (1). [4x]
  2. Install front compartment side rail bracket – rear left. Resistance Spot Welded Full Panel Replacement
  3. Install both front fender rear brackets. Front Fender Rear Bracket Replacement
  4. Install both front fender brackets. Front Fender Bracket Replacement
  5. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair
  1. Paint the repaired area. Basecoat/Clearcoat Paint Systems.
  2. Install all related panels and components.
  3. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
  4. Enable the SIR System. SIR Disabling and Enabling.