Chevrolet AVALANCE 2002 User Manual

2002 Chevrolet Avalanche

Door Frame
Sectioning

IMPORTANT: Section in specified areas

1

only. Sectioning outside of these areas
may compromise the structural integrity
of the vehicle. Do not section in laser
weld (1) areas of door frame sections.

The door frame opening is a unique
laser-weld design incorporating multiple
metal thicknesses 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 quarter panel.
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.

2002 Avalanche 3-1

2002 Chevrolet Avalanche

Windshield Pillar
Sectioning

Removal Procedure

1. Remove all related panels and
components.

2. Restore as much of the damage as
possible to factory specifications.

3. Note the location and remove the
following as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

IMPORTANT: Perform sectioning
in the windshield area 30␣ mm
(1-3/16␣ in.) above the third trim
mounting hole.

IMPORTANT: Take care not to
damage the inner panels or
reinforcements.

4. Cut the pillar in the locations where
sectioning is to be performed.

5. Locate and drill out all factory
welds. Note the number and
location of the welds for installation
of the service part.

6. Remove the damaged Windshield
Pillar section.

30 MM (1-3/16 IN)

50 MM (2 IN)

3-2 2002 Avalanche

50 MM

(2 IN)

100 MM

(4 IN)

100MM

(4 IN)

BACKING PLATE

GAP = ONE AND ONE-HALF TIMES

THE THICKNESS OF THE METAL

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.

PLUG WELDS

13 MM
(1/2 IN)

BACKING PLATE

ORIGINAL PART

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 three­dimensional measuring equipment.

10. Plug weld accordingly.

—continued

2002 Avalanche 3-3

Windshield Pillar Sectioning
Installation Procedure con’t

11. Make 25␣ mm (1␣ in.) stitch welds
along the seam with 25␣ mm (1␣ in.)
gaps between them, then go back
and complete the stitch weld. This
will create a solid joint with minimal
heat distortion.

12. Clean and prepare all welded
surfaces.

IMPORTANT: Prior to refinishing,
refer to the publication GM4901M­D-01 GM Approved Refinish
Materials for recommended
products. Do not combine paint
systems. Refer to paint
manufacturer’s recommendations.

13. Apply an approved anti-corrosion
primer.

14. Apply sealers and refinish as
necessary.

15. Install all related panels and
components.

GAP =
ONE AND ONE-HALF TIMES
MET AL THICKNESS

STITCH WELD

3-4 2002 Avalanche

Front Lower Hinge
Pillar Sectioning

ORIGINAL
PANEL

80 MM (3-1/8 IN)

Removal Procedure

1. Visually inspect and restore as much of
the damage as possible to factory
specifications.

2. Remove all related panels and
components.

3. Note the location and remove the
following as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

4. Measure 80␣ mm (3-1/8 inches) down
from the large wiring harness hole in the
hinge pillar and mark a horizontal line.

5. Cut the pillar in the locations where
sectioning is to be performed.

IMPORTANT: Take care not to damage
the inner panel.

6. Locate, mark and drill out all necessary
factory welds. Note the number of welds
for the installation of the service section.

7. Remove the damaged section of the door
frame opening.

5 MM (3/16 IN)

IMPORTANT: The metal of the hinge
pillar is of a heavy gauge. However, the
tabs can be created using the appropriate
tools.

8. Cut and remove 30␣ mm (1-3/16 inches)
from the flanges on either side of the
remaining section of the original hinge
pillar to create 30␣ mm (1-3/16␣ in.) tabs.
Cut 5␣ mm (3/16␣ in.) wide gaps in the
bottom corners.

30 MM (1-3/16 IN)

9. 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.

WELD TOGETHER

2002 Avalanche 3-5

Front Lower Hinge
Pillar Sectioning

Installation Procedure

1. On the service part, measure 50␣ mm (2␣ in.)
down from the large wiring harness hole in
the hinge pillar and mark a horizontal line.
Cut the hinge pillar along this line.

2. Perform additional sectioning procedures as
necessary to remove the unused areas of
the service part. Refer to Windshield
Sectioning; Center Pillar, Rear Lock Pillar,
and Rocker Sectioning.

NOTICE: In any area damaged beyond
recognition, space plug weld holes every
40␣ mm (1-1/2␣ in.) apart.

3. Drill 8␣ mm (5/16␣ in.) 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 15␣ mm (9/16␣ in.) from the
edge of the cut.

CAUTION: FOAM SEALERS ARE
FLAMMABLE AND SHOULD BE
REMOVED FROM ALL WELD
LOCATIONS.

4. Prepare mating surfaces as necessary.

5. Apply weld-thru primer to all bare-metal
surfaces.

SERVICE
PANEL

50 MM (2 IN)

ORIGINAL
PANEL

6. Position the service section over the
stepped tab on the original hinge pillar,
allowing 30␣ mm (1-3/16 inches) of overlap.
Check fit using three-dimensional
measuring.

7. Plug weld service part in position.

8. Make 25␣ mm (1␣ in.) welds along the seam
with 25␣ mm (1␣ in.) gaps between. Then go
back and complete the stitch weld. This
will create a solid joint with minimal heat
distortion.

9. Clean and prepare all 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 sealers and refinish as necessary.

12. Install all related panels and components.

30 MM (1-3/16 IN)

OF OVERLAP

NEW
SERVICE PANEL

ORIGINAL
PANEL

3-6 2002 Avalanche

Center Pillar
Sectioning

Removal Procedure

1. Remove all related panels and

1

components.

2. Restore as much of the damage as
possible to factory specifications.

3. Note the location and remove the
following as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

IMPORTANT: Take care not to
damage the inner panels or
reinforcements.

4. Cut the Center Pillar in the location
where sectioning is to be performed.

5. Locate and drill out all factory
welds. Note the number and
location of the welds for installation
of the service part.

6. Remove the damaged Center Pillar
section.

2002 Avalanche 3-7

Center Pillar
Sectioning

Installation Procedure

1. Cut the replacement Center 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 Windshield
Sectioning; Front Lower Pillar
Sectioning; Rear Lock Pillar Sectioning;
and Rocker Sectioning.

4. Drill 8␣ mm (5/16␣ in.) plug weld holes
along the sectioning cut on the
remaining original part.

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
FLA␣ MMABLE 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.

50MM

(2 IN)

1

100MM

(4 IN)

8. Fit the backing plate halfway into the
sectioning joint, clamp and plug weld to
the vehicle.

—continued

3-8 2002 Avalanche

PLUG WELDS

ORIGINAL PART

13 MM
(1/2 IN)

BACKING PLATE

GAP =
ONE AND ONE-HALF TIMES
MET AL THICKNESS

STITCH WELD

Center Pillar Sectioning
Installation Procedure con’t

9. Align the Center Pillar to adjacent
panels using three-dimensional
measuring equipment.

10. Plug weld accordingly.

11. Make 25␣ mm (1␣ in.) stitch welds
along the seam with 25␣ mm (1␣ in.)
gaps between them, then go back
and complete the stitch weld. This
will create a solid joint with minimal
heat distortion.

12. Clean and prepare all welded
surfaces.

IMPORTANT: Prior to refinishing,
refer to the publication GM4901M­D-01 GM Approved Refinish
Materials for recommended
products. Do not combine paint
systems. Refer to paint
manufacturer’s recommendations.

13. Apply an approved anti-corrosion
primer.

14. Apply sealers and refinish as
necessary.

15. Install all related panels and
components.

2002 Avalanche 3-9

Rear Lock Pillar
Sectioning

Removal Procedure

1. Remove all related panels and components.

2. Restore as much of the damage as possible to
factory specifications.

3. Note the location and remove the following
as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

IMPORTANT: Take care not to damage the
inner panels or reinforcements.

4. Cut the Rear Lock Pillar in the locations
where sectioning is to be performed.

5. Locate and drill out all factory welds. Note
the number and location of the welds for
installation of the service part.

6. Remove the damaged Rear Lock Pillar
section.

1

3-10 2002 Avalanche

BACKING PLATE

50 MM

(2 IN)

100 MM

(4 IN)

Rear Lock Pillar
Sectioning

Installation Procedure

1. Cut the replacement Rear Lock
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
Windshield Sectioning; Front Lower
Pillar Sectioning; Center Pillar; and
Rocker Sectioning.

4. Drill 8 ␣ mm (5/16␣ in.) plug weld
holes along the sectioning cut on
the remaining original part.

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.

PLUG WELDS

13 MM
(1/2 IN)

BACKING PLATE

8. Fit the backing plate halfway into
the sectioning joint, clamp and plug
weld to the vehicle.

ORIGINAL PANEL

2002 Avalanche 3-11

Rear Lock Pillar Sectioning
Installation Procedure con’t

9. Align the Rear Lock Pillar to
adjacent panels using three­dimensional measuring equipment.

10. Plug weld accordingly.

11. Make 25␣ mm (1␣ in.) stitch welds
along the seam with 25␣ mm (1␣ in.)
gaps between them, then go back
and complete the stitch weld. This
will create a solid joint with minimal
heat distortion.

12. Clean and prepare all welded
surfaces.

IMPORTANT: Prior to refinishing,
refer to the publication GM4901M­D-01 GM Approved Refinish
Materials for recommended
products. Do not combine paint
systems. Refer to paint
manufacturer’s recommendations.

13. Apply an approved anti-corrosion
primer.

14. Apply sealers and refinish as
necessary.

15. Install all related panels and
components.

GAP =
ONE AND ONE-HALF TIMES
THE METAL THICKNESS

STITCH WELD

3-12 2002 Avalanche

Rocker Panel
Sectioning

Removal Procedure

1

1. Remove all related panels and
components.

2. Restore as much of the damage as
possible to factory specifications.

3. Note the location and remove the
following as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

IMPORTANT: Take care not to
damage the inner panels or
reinforcements.

4. Cut the Rocker Panel in the
locations where sectioning is to be
performed.

5. Locate and drill out all factory
welds. Note the number and
location of the welds for installation
of the service part.

6. Remove the damaged Rocker Panel
section.

2002 Avalanche 3-13

Rocker Panel
Sectioning

Installation Procedure

1. Cut the replacement Rocker Panel 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 100␣ mm (4␣ 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 Windshield
Sectioning; Front Lower Pillar Sectioning;
Rear Lock Pillar Sectioning; and Center
Pillar sectioning.

4. Drill 8␣ mm (5/16␣ in.) plug weld holes along
the sectioning cut on the remaining
original part.

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 Rocker Panel to adjacent panels
using three-dimensional measuring
equipment.

10. Plug weld service part in position.

11. Make 25␣ mm (1␣ in.) stitch welds along the
seam with 25␣ mm (1␣ in.) gaps between
them, then go back and complete the
stitch weld. This will create a solid joint
with minimal heat distortion.

12. Clean and prepare all welded surfaces.

IMPORTANT: Prior to refinishing, refer to
the publication GM4901M-D-2000 “GM
Approved Refinish Materials” for
recommended products. Do not combine
paint systems. Refer to paint manufacturer’s
recommendations.

13. Apply an approved anti-corrosion primer.

14. Apply sealers and refinish as necessary.

15. Install all related panels and components.

100 MM

(4 IN)

BACKING PLATE

GAP = ONE AND ONE-HALF TIMES
THE THICKNESS OF THE METAL

3-14 2002 Avalanche