Chevrolet Silverado / GMC Sierra. Service manual - part 1291

Fig. 81: Stepping Tabs 
Courtesy of GENERAL MOTORS CORP. 

12. Step the tabs (1) inward to allow the door frame opening service section to fit over the original hinge 

pillar.  

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Installation Procedure 

Fig. 82: Cutting Hinge Pillar 
Courtesy of GENERAL MOTORS CORP. 

1. On the service body side, measure 40 mm (1 9/16 in) down from the large wiring harness hole in the 

hinge pillar. Mark a horizontal line. Cut the hinge pillar (1) along this line.  

2. Perform additional sectioning procedures as necessary to remove the unused areas of the service part. 

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Fig. 83: Plug Weld Holes & Service Part 
Courtesy of GENERAL MOTORS CORP. 

3. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the remaining original part (2). Locate 

these holes approximately 25 mm (1 in) (a) from the edge and spaced 40 mm (1 1/2 in) apart. 

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Fig. 84: Drilling Plug Weld Holes 
Courtesy of GENERAL MOTORS CORP. 

4. Drill 8 mm (5/16 in) plug weld holes in the service part, as necessary, in the locations noted from the 

original panel and along the sectioning cut.  

5. Prepare all attachment surfaces, as necessary.  

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

Treatment and Repair . 

IMPORTANT: If the location of the original plug weld holes cannot be determined, or if 

structural weld-thru adhesive was present, space the plug weld holes 
every 40 mm (1 1/2 in) apart.

 

2008 Chevrolet Silverado 1500 

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

Silverado