1 999 Chevrolet Silverado and GMC Sierra

Panel Identification ..................................................... 1-1 Radiator Support Assembly ........................................ 1-2 Door Frame Opening .................................................... 1-3 Door Hinge Replacement ............................................. 1-8 Magnesium Instrument Panel Support .................... 1-12 Steering Column Intermediate Shaft ....................... 1-13 Frame Service ............................................................. 1-14 Body Dimensions ........................................................ 1-17 Frame Dimensions ...................................................... 1-20 Appendix ..................................................................... 1-24

Panel Identification
Two-Sided Galvanized Steel

Thermoplastic Olefin

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-1

Radiator Support Assembly

The radiator support assembly is made of aluminum alloy. Minor damage can be repaired with ER-4043 welding wire and 100 percent argon shielding gas. The upper tie-bar and vertical support portion of the radiator support assembly (Fig. 1.1) are bolt-on components. They are available as part of the radiator support assembly, or can be ordered separately.

Upper tie-bar

Vertical support

Fig 1.1 Aluminum radiator support

1-2

1999 Chevrolet Silverado/GMC Sierra Collision Repair

Door Frame Opening

The door frame opening is a unique laser welded design incorporating multiple metal thickness to ensure the structural integrity of the cab. The door frame can be replaced at factory seams, but requires the removal of the roof panel, windshield and cab rear corner. Sectioning procedures have been developed as a more cost-effective alternative to complete replacement. The specific area to be sectioned is determined by the extent of the damage to the vehicle.

General Sectioning
Notice: This procedure does not apply to the front hinge pillar. See front hinge pillar sectioning procedure.
When sectioning the door frame opening in areas where there is no inner reinforcement, a 100mm (4 inch) backing plate must be installed behind the joint to ensure a solid and secure weld. Backing plates can be cut from the unused portion of the door frame opening service part. The specific areas to be sectioned are determined by the extent of damage to the vehicle.

Windshield Area Sectioning

Sectioning of door frame in windshield area can be performed 30mm (1-3/16 inches) above the third trim mounting hole. Follow general sectioning procedures using a 50mm (2 inch) backing plate with plug welds located 15mm (19/32 inch) from the edge of the cut lines and a 25mm (1 inch) overlap (Fig. 1.2).

Important: Sectioning is only recommended for the outer panel. If any inner panel is damaged beyond repair it should be replaced at factory seams.

Notice: To ensure a secure weld, sectioning joints should have a gap of approximately one and one-half times the thickness of the metal (Fig. 1.3). Trim parts as necessary to achieve this. Make certain to plug weld backing plates to both the new and original sections. This may require drawing the plate flat against the sections using a screw to temporarily secure the joint for welding.

100mm (4 in) Backing Plate

30mm

50mm

Gap = one and one-half times the thickness of the metal

Fig. 1.3 General sectiong sleeve

Fig. 1.2 Windshield area sectioning

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-3

Door Frame Opening

General Sectioning, continued

Notice: Sectioning should not take place in the shaded areas (Fig. 1.4). Sectioning in these areas may compromise the structural integrity of the vehicle.
REMOVE OR DISCONNECT

Cut the door frame opening where sectioning is to be performed (Fig. 1.4). Notice: Take care not to damage the inner panels or reinforcements. Locate, mark and drill out all factory welds. Note the number and location of welds for installation of the service part. Remove the damaged area of door frame opening. Notice: Do not section within 100mm (4 inches) of laser welds (Fig. 1.4).

1 2 3 4

Remove all related panels and components. Visually inspect and restore as much of the damage as possible to factory specifications. Remove sealers, sound deadeners and anticorrosion materials as necessary. After pulling and straightening operations have been completed, and before removal of damaged panel, check, measure and compare the service part to original part to choose the areas where sectioning can best be performed.

30mm

Laser Weld Laser Weld

50mm

Laser Weld SECTIONING SHOULD NOT TAKE PLACE IN BLUE SHADED AREAS

Laser Weld

Fig. 1.4 Laser welded areas and sectioning locations

1-4

1999 Chevrolet Silverado/GMC Sierra Collision Repair

Door Frame Opening

General Sectioning, continued

INSTALL OR CONNECT

1 2 3

On the service part, mark cut lines at the recommended locations for sectioning. Cut the panels to be sectioned. Cut 100mm (4 inch) sleeves from the unused section of service part. If necessary, remove the flanges on both sides of this sleeve and modify as necessary so that it will fit under the sectioning joint. Notice: In any area damaged beyond recognition, space plug weld holes every 40mm (1-1/2 inches) apart. On the service part, drill 8mm (5/16 inch) plug weld holes as necessary in the locations noted from the original part. Also, drill plug weld holes along the sectioning cuts on both the service part and the remaining original panels. These should be located approximately 25mm (1 inch) from the edge of the cuts. Prepare mating surfaces with a suitable weldthru primer and slide the sleeves 50mm (2 inches) beneath the remaining original

panels. Position the service part, allowing it to overlap the exposed 50mm (2 inches) of the sleeves, leaving a gap one and one-half times the thickness of metal for welding. Check fit using three-dimensional measuring. Plug weld accordingly with frequent measurements to ensure proper fit. Stitch weld along the sectioning joints (Fig. 1.5). Make 25mm (1 inch) welds along the seam with 25mm (1 inch) gaps between. Then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion. Clean and prepare welded surfaces. Important: Prior to refinishing, refer to GM P/N 4901 M-D Refinish Manual for recommended products.

8 9

Apply approved anti-corrosion primer. Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. 10 Reinstall all related panels and components.

Fig. 1.5 Sectioning joint

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-5

Door Frame Opening

Original Panel

Lower Front Hinge Pillar Sectioning

REMOVE OR DISCONNECT

1 2
80mm

3 4

5
Fig. 1.6 Cut the hinge pillar

7 8

30mm

5mm

Remove all related panels and components. Visually inspect and restore as much of the damage as possible to factory specifications. Remove sealers, sound deadeners and anticorrosion materials as necessary. Measure 80mm (3 1/8 inches) down from the large wiring harness hole in the hinge pillar and mark a horizontal line. Cut the hinge pillar along this line, taking care not to damage the inner panel (Fig. 1.6). Perform additional sectioning procedures as necessary to remove damaged areas of the door frame opening. Locate, mark and drill out all necessary factory welds. Note the number of welds for the installation of the service section. Remove the damaged section of the door frame opening. Cut and remove 30mm (1-3/16 inches) from the flanges on either side of the remaining section of the original hinge pillar to create 30mm (1-3/16 inch) tabs. Cut 5mm (3/16 inch) wide gaps in the bottom corners (Fig 1.7). Step the tabs inward to allow the door frame opening service section to fit over the original hinge pillar. Weld the tabs together along the edges (Fig 1.8). Important: The metal of the hinge pillar is of a heavy gauge. However, the tabs can be created using the appropriate tools.

Fig. 1.7 Create tab on hinge

Weld Together

Fig. 1.8 Weld corners

1-6

1999 Chevrolet Silverado/GMC Sierra Collision Repair

Door Frame Opening

Lower Front Hinge Pillar Sectioning, continued

INSTALL OR CONNECT

Service Panel

On the service part, measure 50mm (2 inches) down from the large wiring harness hole in the hinge pillar and mark a horizontal line. Cut the hinge pillar along this line (Fig. 1.9). Perform additional sectioning procedures as necessary to remove the unused areas of the service part. Notice: In any area damaged beyond recognition, space plug weld holes every 40mm (1-1/2 inches) apart. Drill 8mm (5/16 inch) plug weld holes as necessary in the locations noted from the original section. Also drill plug weld holes along the hinge pillar sectioning cut of the service part. These should be located approximately 15mm (9/16 inch) from the edge of the cut. Prepare mating surfaces with a suitable weldthru primer and position the service section over the stepped tab on the original hinge pillar, allowing 30mm (1-3/16 inches) of overlap (Fig. 1.10). Check fit using three-dimensional measuring. Plug weld accordingly with frequent measurements to ensure proper fit. Stitch weld along the entire joint. Make 25mm (1 inch) welds along the seam with 25mm (1 inch) gaps between. Then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion (Fig. 1.11). Complete all other welds and sectioning procedures as necessary. Clean and prepare welded surfaces. Important: Prior to refinishing, refer to GM P/N 4901 M-D Refinish Manual for recommended products.
Fig. 1.9 Hinge pillar

50mm

Original Panel

5 6

New Service Panel

Fig. 1.10 Stepped tab

7 8

9 Apply approved anti-corrosion primer. 10 Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. 11 Reinstall all related panels and components.

30mm of overlap

Original Panel

Fig. 1.11 Seamed joint

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-7

Door Hinge Replacement

Body Side
REMOVE OR DISCONNECT

1 2 3

Remove door from body. (Refer to appropriate service manual.) Visually inspect and restore as much of the damage as possible to factory specifications. Lightly hand-sand existing hinge with 100 grit or finer sandpaper to locate the four welds attaching hinge to the pillar (Fig. 1.12). Center punch each of the four weld marks on the original hinge. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible. Notice: Do not drill into the hinge pillar drill through hinge ONLY (Fig. 1.13). If necessary, use a chisel to separate the hinge from the pillar.

At each punch location, drill through hinge ONLY, using a 13mm (1/2 inch) rotabroach hole saw or equivalent. (Fig. 1.13). Remove all remaining weld material from pillar surface to ensure a flush fit of the service hinge.

Fig. 1.12 Hand sand to locate welds on body hinge

Hinge Pillar Hinge Reinforcement Typical Mig Weld

Drill through hinge only

13mm (1/2 inch) Rotabroach Bit

Fig. 1.13 Drill hinge using rotabroach hole saw

1-8

1999 Chevrolet Silverado/GMC Sierra Collision Repair

Door Hinge Replacement

Body Side, continued

INSTALL OR CONNECT

1 2

3 4 5

Repair any damage done to the pillar during drilling or removal. Position the service template on the hinge pillar using 3Ms Repositionable Adhesive (Part #6091), or equivalent. Center punch each stud location on the hinge pillar according to the template. Drill 3mm (1/8 inch) pilot hole at each center punch location. Using pilot hole as guide, drill a 11.5mm (29/64 inch) hole through hinge pillar at stud locations. Must be exact drill size (Fig. 1.14). Clean and prepare all bare metal surfaces. Important: Prior to refinishing, refer to GM P/N 4901 M-D Refinish Manual for recommended products.

12 Clean and prepare all surfaces as necessary for refinish. 13 Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. 14 Install and align all related panels and components.

7 8

Apply approved anti-corrosion primer. Feed fish wire (such as GM part #15017229) through hinge stud hole and out conduit hole in the pillar (Fig. 1.15). 9 Install stud (part #15017230) supplied with service hinge into wire end and pull the stud into position. Draw the studs tight through the pillar using nuts (part #11516746) supplied. Remove each service nut. 10 Apply a full-bodied caulk to the entire hinge mounting surface to ensure a proper seal. 11 Install hinge using nuts supplied, torque to 25 Nm (20 FT. LB.) (Fig. 1.16).

Fig. 1.15 Feeding fish wire

Pillar

Hinge Reinforcement

Hinge Nuts Studs

Fig. 1.14 Drill hinge pillar to 11.5mm

Fig. 1.16 Install door hinge body side

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-9

Door Hinge Replacement

Door Side
REMOVE OR DISCONNECT

1 2 3

Remove door from body. (Refer to appropriate service manual.) Visually inspect and restore as much of the damage as possible to factory specifications. Lightly hand-sand existing body hinge with 100 grit or finer sandpaper to locate the four welds attaching hinge to door (Fig. 1.17). Center punch each of the four weld marks on the original hinge base. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible. Notice: Do NOT drill into the door drill through hinge ONLY (Fig. 1.18). If necessary, use a chisel to separate the hinge from door.

At each punch location, drill through hinge base only using a 13mm (1/2 inch) rotabroach saw, or equivalent. (Fig. 1.18) Remove all remaining weld from door surface to ensure a flush fit of service hinge.

Fig. 1.17 Hand-sand to locate welds on door hinge

Door Hinge

Hinge Reinforcement

Drill through hinge only

Typical Mig Weld

13mm (1/2 inch) Rotabroach Bit

Fig. 1.18 Rotabroach

1-10

1999 Chevrolet Silverado/GMC Sierra Collision Repair

Door Hinge Replacement

Door Side, continued

INSTALL OR CONNECT

1 2

4 5 6

Repair any damage done to door during drilling or removal. Clean and prepare hinge and backing plate mounting surfaces to ensure a flush fit of the service hinge. Position the service template on door using 3M Repositionable Adhesive (part #6091), or equivalent. Center punch each hole location on the door according to the template. Drill a 3mm (1/8 inch) pilot hole at each center punch location. Using pilot hole as guide, drill a 13mm (1/2 inch) hole through door at pilot locations (Fig. 1.19). Clean and prepare all surfaces, as necessary for refinish. Important: Prior to refinishing, refer to GM P/N 4901 M-D Refinish Manual for recommended products.

Fig. 1.19 Drill door to 13mm (1/2 inch)

8 9

Apply approved anti-corrosion primer. Apply full-bodied caulk to the entire hinge mounting surface to ensure a proper seal. 10 Align the hinge and backing plate with the holes in the door. Install bolts. Tighten bolts to 25 Nm (20 ft. lb.) (Fig. 1.20). 11 Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. 12 Install and align all related panels and components.

Door

Hinge Reinforcement Hinge

Backing Plate

Fig. 1.20 Install door hinge door side

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-11

Magnesium Instrument Panel Support

Instrument Panel Support
The Instrument Panel Support is a one-piece component comprised of a magnesium steering column support (Fig. 1.21), which holds the instrumentation and steering column; a dieformed tube attaches to the passenger side and supports the dashboard. This assembly functions as a structural cross-vehicle beam, air-bag support, and instrument panel carrier, which consolidates many different steel and plastic components. The magnesium instrument panel support is designed to deform and absorb energy generated by a severe impact.

Notice: Under no circumstance is the magnesium support to be repaired in any way. If any of the following conditions are present after a collision, the magnesium support must be replaced: Steering column capsules have released or column has collapsed. The steel knee bolster brackets are bent. The parts which attach to the magnesium support do not fit.

Die-formed tube Magnesium column support

Knee bolster

Column capsules

Fig 1.21 Instrument panel support

1-12

1999 Chevrolet Silverado/GMC Sierra Collision Repair

Steering Column Intermediate Shaft

The redesigned steering column has a convoluted style intermediate shaft (Figs. 1.22 and 1.23). The C1500 has one convoluted area, while all other models have two. These convoluted areas must be inspected for damage after every airbag deployment. Test the straightness of the shaft at various locations along the convoluted area by placing a straight edge against the intermediate shaft. The intermediate shaft must be replaced if bent or damaged.

Fig. 1.22 C1500 intermediate shaft

Fig. 1.23 C2500 and K-series intermediate shaft

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-13

Frame Service
The redesigned frame of the C/K Pickup incorporates hydroformed technology, utilizing high-strength, low-alloy steel in the middle and rear sections; a replaceable, hydroformed, energy absorbing crush cap at the front of the frame (1500 series only); and a rear section that is replaceable at factory seams as a one-piece assembly.

Front Crush Cap Replacement C/K 1500

REMOVE OR DISCONNECT

1 2
Fig. 1.24 Remove core support mounting bracket

Remove all related panels and components. Visually inspect and restore all damage rearward of crush cap. Restore to factory specifications using three-dimensional measuring. Notice: If crush cap is bent or damaged in any way it must be replaced. Remove core support mounting bracket (Fig. 1.24). Notice: Use caution to not damage the rail. Locate brake line mounting hole on top of rail. Measure forward 155mm (6-1/8 inches) This is your cut line. Scribe a line following frame contour 360 degrees around frame rail and forward of cross tube. Remove crush cap at cut-line using die grinder or appropriate tool. Notice: Use caution to not damage the cross tube (Fig. 1.25). Grind remaining weld off cross tube where damaged crush cap was removed (Fig. 1.26).

155mm

Fig. 1.25 Remove damaged crash cap

Fig. 1.26 Remove remaining weld

1-14

1999 Chevrolet Silverado/GMC Sierra Collision Repair

Frame Service

Front Crush Cap Replacement, continued

INSTALL OR CONNECT

2 3

Drill four plug weld holes (2 top, 2 bottom), 15mm from cut line and 50mm (2 inches) apart on existing frame rail (Fig. 1.27). Prepare all bare metal surfaces with a suitable weld-thruh primer. Install and position replacement crush cap using three-dimensional measuring. Notice: Retain a gap of one-and-one-half times the metal thickness at the butt joint when attaching the service part to the vehicle (Fig. 1.28). Tack weld part into position at initial plug weld holes. Recheck service part for proper dimensions, then stitch weld along entire sectioning joint. Make 25mm (1 inch) welds along the seam with 25mm (1 inch) gaps between. Go back and complete stitch weld. This will create a solid joint with minimal heat distortion. Clean and prepare welded surfaces. Important: Prior to refinishing, refer to GM P/N 4901 M-D Refinish Manual for recommended products.

13mm

50mm

4 5

Fig. 1.27 Drill four plug weld holes

7 8

Apply approved anti-corrosion primer. Position new core support mounting bracket and weld in place according to specified dimensions. 9 Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. 10 Replace related panels and components. Important: The replacement bumper bracket (Fig. 1.28) is a bolt-on component that must be ordered separately.

GAP = one and one-half times the thickness of the metal

Fig. 1.28 Replacement crush cap

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-15

Frame Service

Rear Module Replacement

Important: All steps are performed on both rails for complete module replacement.
REMOVE OR DISCONNECT

Important: It is necessary to monitor specified dimensions by frequently performing threedimensional measuring throughout procedures.
INSTALL OR CONNECT

1 2

Remove all related panels and components. Visually inspect and restore all damage forward of rear module to factory specifications using three-dimensional measuring. Separate center and rear module at factory stitch weld with die grinder or appropriate tool (Fig. 1.29). Pry lower edge of cross tube bracket down to allow rear module to separate from center module (Fig. 1.29). Remove damaged rear module.

1 2 3 4 5 6

Prepare all bare metal surfaces with a suitable weld-through primer. Position and install replacement module using three-dimensional measuring. Restore bracket flange for flush fit to new service part. Tack weld into position. Recheck service part for proper dimensions. Stitch weld entire sectioning joint. Clean and prepare welded surfaces. Important: Prior to refinishing, refer to GM P/N 4901 M-D Refinish Manual for recommended products. Apply approved anti-corrosion primer. Apply sealers and refinish as necessary. Do not combine paint systems. Refer to paint manufacturers recommendations. Install all related panels and components.

7 8

Bend flange down

Factory joint

FRT

Cross tube bracket

Fig. 1.29 Rear module

1-16

1999 Chevrolet Silverado/GMC Sierra Collision Repair

Body Dimensions

A L: 405 W: 794 H: 1273

I L: W: H: 1735 889 972 E H L: 1715 W: 868 H: 892 L: W: H: 80 860 1022

D L: W: H: 387 794 1274 B L: W: H: 495 770 1266

L: W: H:

G 1086 860 569 L: W: H:

C L: 444 W: 770 H: 1270 F 117 868 930

E L: W: H: 80 860 1022

J L: 1063 W: 876 H: 1004

F L: W: H: 117 868 930

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-17

Body Dimensions

1357

L L: W: H: 322 679 1758

1566

1566 690

1455

L: W: H:

213 728 1324

WINDSHIELD OPENING

1277

L: 1208 W: 638 H: 1774

412 1486 1486 397

M L: 1253 W: 790 H: 1387

1579

BACK OF CAB (REAR VIEW)

1-18

1999 Chevrolet Silverado/GMC Sierra Collision Repair

Body Dimensions

Cab Hole Identification

Letter

Feature

Usage

A B C D E F G H I J K L M N

12mm hole 11mm hole 12mm x 8mm slot 11mm x 14mm slot 8mm weld nut 54mm hole 8mm weld nut 8mm weld nut 34mm hole 8mm weld nut

Cowl drain vent retainer hole Fender bracke attachment hole Cowl drain vent retainer hole Fender brack attachment hole Check strap mount hole Front door wiring harness hole Access door striker forward mount hole Access door check strap mount hole Access door wiring harness hole Front door striker upper mount hole Corner of windshield pillar flange Front roof flange corner Lower corner backglass flange Rear roof flange corner

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-19

1-20
0
D C L: 99 W: 670 H: 497 I L: 4368 W: 496 H: 773 L: 0 W: 523 H: 382 H L: 4043 W: 496 H: 649 G L: 3365 W: 499 H: 659 E L: 2012 W: 600 H: 772 F L: 2458 W: 522 H: 609 N L: 973 W: 0 H: 392 K L: 1971 W: 0 H: 755 J L: 3958 W: 0 H: 747 M L: 999 W: 685 H: 481 L L: 1795 W: 685 H: 616 T L: 793 W: 451 H: 686 U L: 489 W: 450 H: 642 X L: 469 W: 553 H: 450 Y L: 1794 W: 553 H: 460 Z L: 2502 W: 659 H: 507 AA L: 2726 W: 553 H: 675 BB L: 3421 W: 531 H: 720 CC L: 4106 W: 659 H: 580

A L: 1327 W: 387 H: 565

B L: 1311 W: 590 H: 659

Q L: 1458 W: 275 H: 594

Frame Dimensions

C1500 Silverado and Sierra Extended Cab Long Box

1999 Chevrolet Silverado/GMC Sierra Collision Repair

P L: 1441 W: 387 H: 565

O L: 1179 W: 385 H: 487

R L: 1456 W: 370 H: 732

S L: 1150 W: 387 H: 700

V L: 1482 W: 439 H: 587

W L: 1176 W: 412 H: 566

Frame Dimensions

C1500 Silverado and Sierra Extended Cab Long Box Frame Hole Identification Chart

Letter

Feature

Usage

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA BB CC

32mm Hole 41mm x 39mm Hole 41mm x 39mm Hole 17mm Hole 17.5mm Hole 20mm x 35mm Hole 11mm Hole 15.5mm Hole 18mm x 20mm Slot 25mm x 40mm Slot 10mm Hole 41mm x 39mm Hole 41mm x 39mm Hole 18mm x 22mm 9mm Hole 13mm Hole 13mm x 27mm Slot 16mm Weld Nut 8mm Hole 15mm x 34mm Slot 15mm x 34mm Slot 13mm Hole 18mm x 35mm Slot 25mm Hole 14mm Hole 18mm Hole 25mm x 40mm Slot 25mm x 40mm Slot 15mm Hole

Bottom surface of rail Body mount bracket Body mount bracket Bottom surface of rail (Front) Box mount bracket Bottom surface of rail Bottom surface of rail Bottom surface of rail Top surface of rail Bottom surface of spare wheel bracket Bottom surface of cross bar Body mount bracket Body mount bracket Bottom surface of crossmember (engine) Top surface of rail Bottom surface tow hook attachment Bottom slot bumper attachment Bumper attachment Top of rail Front upper control arm attachment bracket Rear upper control arm attachment bracket Side of rail tow hook attachment Side of rail shipment slot Side of rail Side of rail Front shackle mounting bracket Side of rail Side of rail Rear shackle mounting bracket

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-21

1-22
0
B L: 99 W: 670 H: 500 L: 0 W: 553 H: 370 H L: 4368 W: 496 H: 773 C F L: 3357 W: 500 H: 621 D L: 2012 W: 600 H: 775 E L: 2458 W: 522 H: 562 G L: 4043 W: 496 H: 649 M L: 463 W: 242 H: 353 J L: 1968 W: 0 H: 696 I L: 3957 W: 0 H: 750 L L: 999 W: 685 H: 484 K L: 1793 W: 686 H: 616 T L: 449 W: 401 H: 672 W L: 469 W: 553 H: 450 X L: 1794 W: 553 H: 460 Y L: 2496 W: 660 H: 495 Z L: 2726 W: 552 H: 674 AA L: 3421 W: 531 H: 720 BB L: 4106 W: 660 H: 560

Frame Dimensions

A L: 1319 W: 590 H: 593

Q L: 1459 W: 275 H: 592

N L: 742 W: 0 H: 370

C2500 Silverado and Sierra Extended Cab Long Box

1999 Chevrolet Silverado/GMC Sierra Collision Repair

P L: 1327 W: 411 H: 470

O L: 1117 W: 403 H: 462

R L: 1456 W: 370 H: 735

S L: 840 W: 428 H: 704

U L: 1408 W: 454 H: 524

V L: 1142 W: 443 H: 547

Frame Dimensions

C2500 Silverado and Sierra Extended Cab Long Box Frame Hole Identification Chart

Letter

Feature

Usage

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA BB

39mm x 41mm Hole 39mm x 41mm Hole 17mm Hole 17.5mm Hole 39mm x 24mm Slot 11mm Hole 15.5mm Hole 20mm x 18mm Slot 40mm x 25mm Slot 10mm Hole 41mm x 39mm Hole 41mm x 39mm Hole 13.5mm Hole 40mm x 25mm Slot 9mm Hole 32mm Hole 13mm x 27mm Slot 16.5mm Hole 34mm x 15mm Slot 34mm x 15mm Slot 13mm Hole 35mm x 18mm Slot 25mm Hole 14mm Hole 18mm Hole 40mm x 25mm Slot 40mm x 25mm Slot 15mm Hole

Body mount bracket Body mount bracket Bottom surface of rail (Front) Box mount bracket Bottom surface of rail Bottom surface of rail Bottom surface of rail Top surface of rail Bottom surface of spare wheel bracket Bottom surface of crossmember Bottom surface of cross bar Body mount bracket Body mount bracket Bottom surface of crossmember (engine) Top surface of rail Bottom surface of rail Bottom of bumper mount bracket Top of bumper mount bracket Front upper control arm attachment bracket Rear upper control arm attachment bracket Side of rail two hook attachment Side of rail shipment slot Side of rail Side of rail Front shackle mounting bracket Side of rail Side of rail Rear shackle mounting bracket

1999 Chevrolet Silverado/GMC Sierra Collision Repair

1-23

Appendix
Fastener Tightening Specifications
Application Outer Tie Rod to Knuckle Idler Arm to Frame Bolt Outer Tie Rod Adjuster Sleeve Pitman Arm Retaining Nut Idler Arm to Frame Bolt Relay Rod to Idler and Pitman Arm Nut Hose Fittings to Steering Gear Pinch Bolt to Intermediate Shaft Steering Gear Retaining Bolts Axle Shaft Nut (K Models) Brake Hose Bracket Bolt Brake Hose Clamp Bolts Hub and Bearing Assembly to Steering Knuckle Bolts Lower Ball Joint to Steering Knuckle Nut Lower Control Arm Bumper (C Models) Lower Control Arm to Frame Nuts & Bolts Outer Tie Rod Nut Shock Absorber to Control Arm Nuts (K Models) Shock Absorber Upper Nut Shock Absorber to Control Arm Bolts (C Models) Stabilizer Bar Bracket to Frame Nuts & Bolts Stabilizer Link Nuts Torsion Bar Support Link Nuts (25 Series K Models) Torsion Bar Support Mounting Nuts (15 Series K Models) Upper Ball Joint Nuts (C Models) Upper Ball Joint to Steering Knuckle Nut Upper Control Arm to Frame Nuts & Bolts Leaf Spring to Bracket Nuts Leaf Spring to Shackle Nuts Shackle to Bracket Nuts Shock Absorber Lower Nuts Shock Absorber Upper Nuts U Bolt Nuts (Gas Engine) U Bolt Nuts (Diesel) Front Bumper to Frame Bracket Bolt Front Bumper Bracket to Brace Bolt Rear Bumper Bracket to Frame Side Bolt Rear Bumper Bracket to Frame Nut Rear Bumper Bracket to Frame Lower Bolt Weight Distribution Hitch to Frame Nuts & Bolts Seat Riser to Floor Stud Nuts Rear Seat Track to Floor Nuts Seat Belt Attachments Seat Belt Anchors Seat Back to Recliner Bolts N.m 45 70 68 250 70 63 28 62 95 200 9 12 180 72 32 165 62 90 20 25 33 20 95 95 24 50 125 125 95 95 95 95 80 120 85 55 50 90 125 125 55 55 53 53 53 Lb Ft 33 52 50 184 52 46 21 46 70 148 133 53 23 121 46 66 15 19 24 15 70 70 18 37 92 92 70 70 70 70 59 89 63 41 37 66 92 92 41 41 39 39 39 80 106 Lb In

1-24

1999 Chevrolet Silverado/GMC Sierra Collision Repair