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2002 Avalanche 3-3
Windshield Pillar
Sectioning
Installation Procedure
1. Cut the replacement pillar in
corresponding locations to fit the
remaining original panel. The
sectioning joint should be trimmed
to allow a gap of one and one-half
times the metal thickness at the
sectioning joint.
2. Create a 50␣ mm (2␣ in.) backing
plate from the unused portion of the
service part. Trim the backing plate
as necessary to fit behind the
sectioning joint.
3. Perform additional sectioning
procedures as necessary. Refer to
Center Pillar Sectioning; Front
Lower Pillar Sectioning; Rear Lock
Pillar Sectioning; and Rocker
Sectioning.
4. Drill 8␣ mm (5/16␣ in.) holes for plug
welding in the original part. Locate
these holes approximately 13␣ mm
(1/2␣ in.) from the edge of the
sectioning cuts and spaced 40␣ mm
(1-1/2␣ in.) apart.
5. Drill 8␣ mm (5/16␣ in.) plug weld
holes in the service panel as
necessary in the locations noted
from the original panel and along
the sectioning cut.
CAUTION: FOAM SEALERS ARE
FLAMMABLE AND SHOULD BE
REMOVED FROM ALL WELD
LOCATIONS.
6. Prepare the mating surfaces, as
necessary.
7. Apply weld-through primer to all
bare metal surfaces.
8. Fit the backing plate halfway into
the sectioning joint, clamp and plug
weld to the vehicle.
9. Align the Windshield Pillar to
adjacent panels using three-
dimensional measuring equipment.
10. Plug weld accordingly.
—continued
PLUG WELDS
13 MM
(1/2 IN)
ORIGINAL PART
BACKING PLATE
50 MM
(2 IN)
100 MM
(4 IN)
100MM
(4 IN)
BACKING PLATE
GAP = ONE AND ONE-HALF TIMES
THE THICKNESS OF THE METAL