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2002 Avalanche 3-31
Rail End
Front Crush Cap
Replacement
Removal Procedure
1. Remove all of the related panels and the
components.
IMPORTANT: If the crush cap is bent or
damaged in any way you must replace the
crush cap.
2. Visually inspect the damage. Use three-
dimensional measuring in order to
restore all of the damage rearward of the
Crush Cap to the factory specifications.
IMPORTANT: Use care not to damage
the rail.
3. Remove the core support mounting
bracket.
4. Locate the brake line attachment hole
on the top of the rail. Measure forward
155 mm (6-1/8␣ in.). This is the cut line.
5. Scribe a line 360 degrees around the
frame rail and in front of the cross tube.
CAUTION: DO
NOT DAMAGE THE
CROSS TUBE
6. Remove the Crush Cap at the cut-line
and the forward edge of the cross tube.
7. Grind the remaining weld off of the
cross tube where you removed the
damaged Crush Cap.
155 MM
(6 IN)