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3-32 2002 Avalanche
13mm
50mm
GAP = ONE AND ONE-HALF TIMES
THE THICKNESS OF THE METAL
Rail End
Front Crush Cap
Replacement
Installation Procedure
1. Drill 4 plug weld holes (2 at the top and
2 at the bottom), 13 mm (1/2␣ in.) from
the cut line and 50 mm (2␣ in.) apart on
the existing frame rail.
2. Prepare all of the bare metal surfaces
with a suitable weld through primer.
IMPORTANT: The replacement bumper
bracket is a bolt-on component that must
be ordered separately.
IMPORTANT: Retain a gap of one and
one-half times the metal thickness at the
butt joint when attaching the service part
to the vehicle.
3. Install and position the replacement
Crush Cap using three-dimensional
measuring.
4. Tack weld the part into position at the
initial plug weld holes.
5. Inspect the service part for proper
dimensions.
6. Stitch weld along the entire sectioning
joint. Make 25 mm (1␣ in.) welds along
the seam with 25 mm (1␣ in.) gaps
between.
7. Complete the stitch weld.
8. Position the new core support mounting
bracket and weld the bracket in place
according to the specified dimensions.
9. Clean and prepare the welded surfaces.
IMPORTANT: Prior to refinishing, refer
to the publication GM4901M-D-01 GM
Approved Refinish Materials for
recommended products. Do not combine
paint systems. Refer to paint
manufacturer’s recommendations.
10. Apply an approved anti-corrosion primer.
11. Apply the sealers.
12. Refinish the welded surfaces as
necessary.
13. Replace the related panels and the
components.