8-19-04 - 1st Copy - Genuine GM Parts

Frame Procedures

Repair Instructions

Frame Sectioning - Front Full Frame (Chevrolet SSR)

Removal Procedure The service assemblies for the left and the right front frame rails are pre-sleeved, mild steel, hydro-formed parts, which correlate directly with the die marks located on the front frame rails. The assemblies include pre-welded support mounting brackets for the body and the radiator.

Caution: Refer to Approved Equipment for Collision Repair Caution on page 1-1.

Caution: Refer to Collision Sectioning Caution on page 1-1.

1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones on page 1-118.

Caution: Refer to Battery Disconnect Caution on page 1-1.

2. Disconnect the negative battery cable. 3. Remove all of the related panels and components.

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Frame Procedures

Frame Procedures 2-1

4. Locate the two die-marks on the damaged frame rail. The die marks are located 302 mm (11 7/8 in) rearward from the front frame rail bumper bracket, on the top and bottom side of each rail.

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Important: Line up the masking tape with the point of each die mark arrow as shown.

5. Apply masking tape over the die-marks and down each frame rail side as shown, for the cut location.

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Important: The tape edge facing the rear of the vehicle is the proper cut location. The cut location is not to exceed 302 mm (11 7/8 in) of the front frame section.

6. Cut the damaged frame rail at the rear edge of the tape line using a reciprocating saw or equivalent, as shown.

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2-2 Frame Procedures

7. Remove the damaged frame section.

Frame Procedures

Installation Procedure 1. Grind the existing frame rail sectioning location to a 45 degree angle. 2. Prepare all of the attaching surfaces as necessary.

3. Position the service frame section to the existing frame and clamp in place.

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Frame Procedures 2-3

Important: Inspect the frame measurements three-dimensionally to ensure proper position of the service frame prior to welding. Refer to Dimensions Frame.

4. Continuous-weld the upper and lower horizontal joints from corner to corner.

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5. Continuous-weld the inner and outer vertical joints from corner to corner.

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6. Clean and prepare all of the welded surfaces.

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

8. Install all of the related panels and components.

Caution: Refer to Battery Disconnect Caution on page 1-1.

9. Connect the negative battery cable.

10. Enable the SIR system. Refer to SIR Disabling and Enabling Zones on page 1-118.

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2-4 Frame Procedures

Frame Sectioning - Front Full Frame (Mid size utility 2002 - current, except S/T models)

Removal Procedure The re-designed frame assembly for the new S/T Utility is a mild, steel hydroformed frame assembly. A front frame service section consisting of the left and right frame ends, body, and radiator support mounting brackets and front connecting cross tube is available. If damage permits, locate and cut off the front 420 mm (161/2 in) portion of the frame using the die-mark indicators as a guide. The front and rear body mounts, radiator support mounts, steering gear and transmission cross-member can be ordered and replaced separately.

1. Remove all of the related panels and components including the front bumper assembly.

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Frame Procedures

2. Locate the 2 die-marks on each frame. The die marks are located 420 mm (161/2 in) rearward from each front frame rail end on the top and bottom side of each rail.

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Frame Procedures 2-5

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