GM Service Manual Online
For 1990-2009 cars
Makes 🢒 Chevrolet 🢒 2004 🢒 C-Series Medium Duty Truck C6/7/8 - Mexico 🢒 Body 🢒 Body Front End 🢒 Component Box Replacement

Removal Procedure

    Object Number: 206464 Size: SH
  1. Remove the following components from the components box:
    2. • The top cover bolts
    • The top cover washers
    • The top cover
  2. Remove the following components inside the box:
    3. • Remove the air dryer. Refer to Automatic Level Control Air Dryer Replacement in Air Brakes.
    • Remove the EVAP Canister. Refer to Evaporative Emission Canister Replacement in Engine Controls - 8.1L.
  3. Remove the following components holding the brace to the sides of the box:
    4. • The bolts
    • The washers
    • The nuts
  4. Remove the following components holding the supports to the sides of the box:
    5. • The bolts
    • The washers
    • The nuts
  5. Remove the following components from inside the frame rail:
    6. • The six bolts
    • The washers
    • The nuts
  6. Remove the following components from the frame rail:
    7. • The reinforcements
    • The box sides

Installation Procedure

    Object Number: 206464 Size: SH
  1. Install the following components to the frame rail:
    2. • The box sides
    • The reinforcements

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the following components inside the frame rail:
    3. • The six bolts
    • The washers
    • The nuts

    Tighten
    Tighten the component box nuts to 70 N·m (52 lb ft).

  3. Install the components to the box, if removed.
  4. Use the following components in order to install the supports to the frame:
    5. • The bolts
    • The washers
    • The nuts

    Tighten
    Tighten the component box support nuts to 24 N·m (18 lb ft).

  5. Use the following components in order to install the brace to the sides:
    6. • The bolts
    • The washers
    • The nuts

    Tighten
    Tighten the component box brace nuts to 45 N·m (33 lb ft).

  6. Use the bolts and washers in order the install the following components:
    7. • The side cover
    • The top cover
  7. Use the bolts in order to install the retainers to the box:

    8. Tighten

        • Tighten the top cover bolts to 30 N·m (22 lb ft).
        • Tighten the side cover bolts to 30 N·m (22 lb ft).
        • Tighten the retainer bolts to 23 N·m (17 lb ft).