Chevrolet Silverado / GMC Sierra. Service manual - part 1285

Fig. 60: View Of Outer Door Panel 
Courtesy of GENERAL MOTORS CORP. 

8. Install the door outer panel to the door shell.  

9. Clamp the door outer panel into position, as required. 

IMPORTANT: Do NOT pull the panels apart after being joined 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

  

Fig. 61: Re-Hemming The Hem Flanges 
Courtesy of GENERAL MOTORS CORP. 

10. Using a hammer re-hem the hem flanges around the door shell. 

Continue to hammer in stages along the hem flanges. 

11. Remove the excess adhesive from the door panel area.  

12. Install the door to the vehicle. Inspect the door outer panel for proper alignment; then adjust the 

alignment, as required. Refer to Rear Door Replacement (Extended Cab) or Rear Door Replacement 
(Crew Cab) . 

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Fig. 62: MIG Welding Outer Door Panel 
Courtesy of GENERAL MOTORS CORP. 

13. Using metal-inert gas (MIG), weld the door outer panel to the door frame in the locations noted at the 

upper door frame.  

14. Clean and prepare all welded surfaces. 

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Fig. 63: Applying Anti-Flutter Foam 
Courtesy of GENERAL MOTORS CORP. 

15. Apply Fusor super flexible anti-flutter foam-fast set, Fusor P/N 121/124, or equivalent, in 4-5 evenly 

spaced locations between the door outer panel and the inner safety beam.  

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

Treatment and Repair .  

17. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .  

18. Install all related panels and components.  

19. Enable the SIR system. Refer to SIR Disabling and Enabling .  

20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection 

(w/Single Battery) or Battery Negative Cable Disconnection and Connection (w/Auxiliary Battery) 
or Battery Negative Cable Disconnection and Connection (w/Dual Batteries) .  

REAR SIDE DOOR OUTER PANEL REPLACEMENT (EXTENDED CAB) 

Removal Procedure 

 

2008 Chevrolet Silverado 1500 

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

Silverado