Bumper System: Removal & Installation Chevrolet Silverado 1500

Removal Procedure

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
2. Disconnect the fog lamp electrical connectors, if equipped.
3. Remove the fog lamps, if equipped. Refer to «Fog Lamp Replacement - Front»(ref-238182-S42588124492006072400000) .
4. Loosen the center studs of the push-pins on the air deflector with a flat-bladed screwdriver.
5. Remove the air deflector from the front bumper fascia.

Installation Procedure

1. Position the air deflector onto the front bumper assembly.
2. Fasten the connection ends of the push-pins onto the front bumper deflector.
3. Install the fog lamps, if equipped. Refer to «Fog Lamp Replacement - Front»(ref-238182-S42588124492006072400000) .
4. Connect the fog lamp electrical connectors, if equipped.
5. Lower the vehicle.

1. Open the hood.
2. Remove the grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) .
3. Remove the 2 bumper bolts. Refer to «Bumper Replacement - Front (Old Style)»(ref-238210-S28263092822006072400000) .
4. Remove the 4 bolts (1) from the side support bracket.
5. Remove the 2 push-pins (2) from the top of the fascia.
6. Heat the fascia, using the J 25070 152 mm (6.0 in) from the surface.
7. Apply the heat using a circular motion for about 30 seconds.
8. Remove the fascia from the bumper surface using a plastic, flat-bladed tool.
9. Remove all adhesive from the bumper and the back of the fascia using 3M(tm) Scotch Brite molding adhesive remover disk 3M(tm) P/N 07501 or equivalent.
10. Clean the fascia and bumper surfaces using varnish makers and painters (VMP) naptha.
11. Remove the fascia from the bumper.
12. Remove the air inlet grille panels.
13. Remove the center lower grille (1).

1. Install the center lower grille (1).
2. Install the air inlet grille panels.
3. Warm the bumper surface with the J 25070 152 mm (6.0 in) from the surface to a minimum of 21°C (70°F).
4. Remove the backing from the front end of the bumper.
5. Press the fascia to the bumper surface while continuing to remove the backing.
6. Hand roll the fascia to the bumper to ensure proper adhesion.
7. Inspect the fascia for bonding.
8. Install the fascia to the bumper.
9. Install the 2 push-pins (2) to the top of the fascia.
10. Install the 4 bolts (1) into the side support bracket. Tighten: Tighten the bolts to 2.8 N.m (25 lb in).
11. Install the bumper. Refer to «Bumper Replacement - Front (Old Style)»(ref-238210-S28263092822006072400000) .
12. Install the grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) .
13. Close the hood.

1. Open the hood.
2. Remove the upper air baffle. Refer to «Radiator Air Baffle and Deflector Replacement - Upper»(ref-238207-S10942508972006072400000) .
3. Remove the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) .
4. Remove the front bumper. Refer to «Bumper Replacement - Front (Old Style)»(ref-238210-S28263092822006072400000) .
5. Remove the front bumper fascia cap by depressing all the tabs and pulling up.

1. Position the fascia cap tabs to the slots in the bumper.
2. Install the front bumper cap to the bumper pressing into place until fully seated.
3. Install the front bumper. Refer to «Bumper Replacement - Front (Old Style)»(ref-238210-S28263092822006072400000) .
4. Install the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) .
5. Install the upper air baffle. Refer to «Radiator Air Baffle and Deflector Replacement - Upper»(ref-238207-S10942508972006072400000) .
6. Close the hood.

1. Remove the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) .
2. Disconnect the electrical connector from the fog lamps, if equipped.
3. Remove the retaining bolts (1, 2) from the front bumper.
4. Remove the brace bolt (3) from the front bumper.
5. Remove the front bumper assembly from the vehicle.
6. Remove the air deflector from the bumper if necessary. Refer to «Air Deflector Replacement - Front Bumper Fascia»(ref-238210-S16846337792006072400000) .
7. Remove the fog lamps, if equipped. Refer to «Fog Lamp Replacement - Front»(ref-238182-S42588124492006072400000) .

1. Install the fog lamps, if equipped. Refer to «Fog Lamp Replacement - Front»(ref-238182-S42588124492006072400000) .
2. Install the air deflector to the bumper if necessary. Refer to «Air Deflector Replacement - Front Bumper Fascia»(ref-238210-S16846337792006072400000) .
3. Position the front bumper assembly on the vehicle.
4. Install the retaining bolts (1, 2) to the front bumper. Tighten: Tighten the bracket bolt (1) to 85 N.m (63 lb ft). Tighten the bracket bolt (2) to 85 N.m (63 lb ft). Tighten the brace bolt to 55 N.m (41 lb ft).
5. Connect the electrical connector to the fog lamps, if equipped.
6. Install the front grille Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) .

1. Remove the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) .
2. Disconnect the electrical connector from the fog lamps, if equipped.
3. Remove the retaining bolts (1, 2) from the front bumper.
4. Remove the brace bolt (3) from the front bumper.
5. Remove the front bumper assembly from the vehicle.
6. Remove the air deflector from the bumper if necessary. Refer to «Air Deflector Replacement - Front Bumper Fascia»(ref-238210-S16846337792006072400000) .
7. Remove the fog lamps, if equipped. Refer to «Fog Lamp Replacement - Front»(ref-238182-S42588124492006072400000) .
8. Remove the S clip securing the bumper filler panel to the wheelhouse splash shield.
9. Remove the fastener securing the filler panel to the radiator support.
10. Remove the fastener securing the filler panel to the headlamp bracket.
11. Remove the bumper filler from the vehicle.

1. Install the bumper filler from the vehicle.
2. Install the fasteners securing the filler panel to the headlamp bracket and the radiator support. Tighten: Tighten the filler panel to the headlamp bracket and the radiator support to 9 N.m (80 lb in).
3. Install the fog lamps, if equipped. Refer to «Fog Lamp Replacement - Front»(ref-238182-S42588124492006072400000) .
4. Install the air deflector to the bumper if necessary. Refer to «Air Deflector Replacement - Front Bumper Fascia»(ref-238210-S16846337792006072400000) .
5. Position the front bumper assembly on the vehicle.
6. Install the retaining bolts (1, 2) to the front bumper. Tighten: Tighten the bracket bolt (1) to 85 N.m (63 lb ft). Tighten the bracket bolt (2) to 85 N.m (63 lb ft). Tighten the brace bolt to 55 N.m (41 lb ft).
7. Connect the electrical connector to the fog lamps, if equipped.
8. Install the front grille. Refer to «Grille Replacement (GMC)»(ref-238209-S09461896312006072400000) or «Grille Replacement (Chevrolet)»(ref-238209-S06007732772006072400000) .

Bracket Replacement - Front Bumper (2500)

1. Remove all related panels and components.
2. Remove the damaged bumper bracket.
3. Visually inspect the frame and restore all damage to factory specifications using 3-dimensional measuring.
4. Align the replacement bracket lower bolt holes with tow hook mounting locations and install the bolts (1) supplied.
5. Align the front edge of bracket with front edge of frame and mark upper bolt locations (1) on frame.
6. Rotate the bracket forward and drill 13 mm (1/2 in) holes in frame at upper bolt locations.
7. Rotate the bracket back into position.
8. Install the fasteners supplied. Tighten: Tighten the torque bracket fasteners to 70 N.m (52 lb ft).

Bracket Replacement - Front Bumper (1500)

1. Remove all related panels and components.
2. Remove damaged bumper bracket.
3. Position the service template on the end of the frame rail. Use 3M's Repositionable Adhesive or equivalent.
4. Drill three 13 mm (1/2 in) holes at locations indicated on template.
5. Apply approved anti-corrosion primer to bare metal surfaces.
6. Position replacement bumper bracket.
7. Install the bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).

1. Remove the brace bolt (2) from the front bumper.
2. Remove the brace bolt (3) from the outboard mounting brace plate.
3. Remove the brace (1) from the vehicle.

1. Install the brace (1) to the vehicle.
2. Install the 3 bolts that retain the brace to the bumper and the outboard brace plate. Tighten: Tighten the front bumper brace bolt (2) to 15 N.m (11 lb ft). Tighten the front bumper outboard brace plate bolt (3) to 9 N.m (80 lb in).

1. Remove the step pad.
2. Disconnect the license plate lamp harness.
3. Raise and support the vehicle with suitable safety stands. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
4. Remove the push-pin retainers from the underside of the fascia.
5. Remove the fascia from the impact bar.

1. Align the locator pin of the fascia to the hole in the impact bar.
2. Press the push-pin retainers into the underside of the fascia.
3. Remove the safety stands, and lower the vehicle.
4. Connect the license plate lamp harness.
5. Install the step pad.

1. Remove the bumper. Refer to «Bumper Replacement - Rear»(ref-238210-S38514500732006072400000) .
2. Remove the side molding push-pins.
3. Release the step pad from the bumper by prying up on the step pad.
4. Remove the step pad.

1. Install the step pad to the bumper by pushing down on the clips.
2. Insert the side molding push-pins.
3. Install the bumper. Refer to «Bumper Replacement - Rear»(ref-238210-S38514500732006072400000) .

1. Disconnect the license plate lamp harness.
2. Remove the impact bar nut (1).
3. Remove the plate nuts (2).
4. Remove the lower frame rail to bracket bolt (3).
5. Remove the side frame rail to bracket bolt (4).
6. Remove the rear trailer hitch to bumper bolts (1), if equipped.
7. Remove the rear bumper from the vehicle.

1. Position the rear bumper onto the vehicle.
2. Install the rear trailer hitch to bumper bolts (1), if equipped.
3. Install the impact bar nut (1). Tighten: Tighten the impact bar nut (1) to 50 N.m (37 lb ft).
4. Install the plate nuts (2). Tighten: Tighten the plate nuts (2) to 90 N.m (66 lb ft).
5. Install the lower frame rail to bracket bolt (3). Tighten: Tighten the lower frame rail to bracket bolt (3) to 100 N.m (74 lb ft).
6. Install the side frame rail to bracket bolt (4). Tighten: Tighten the side frame rail to bracket bolt (4) to 40 N.m (30 lb ft).
7. Install the bumper step pad. Refer to «Step Pad Replacement - Rear Bumper»(ref-238210-S02932031662006072400000) .
8. Install the license plate lamp harness.