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1999 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 1999 Chevrolet Silverado/GMC Sierra Collision Repair 1-1 Panel Identification T w o-Sided Galvanized Steel Thermoplastic Olefin 1-2 1999 Chevrolet Silverado/GMC Sierra Collision Repair 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. Fig 1.1 — Aluminum radiator support Upper tie-bar Vertical support 1999 Chevrolet Silverado/GMC Sierra Collision Repair 1-3 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. 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.Ëš1.2). Important: Sectioning is only recommended for the outer panel. If any in ...
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