This body repair manual of 1996-2008 GMC Savana/Chevy Express describes incorporates picture, schemes, tables and descriptions on repairing the body of the GMC/Chevy Vans. GMC Savana and Chevrolet (Chevy Express) are General Motor’s full size vans that were built to replace the GMC Vandura and Chevy Van in 1996. Powered by V6 engine from 4.3L to 6.6L Diesel with a large and spacious body make these vans are very popluar as a work vehicle. It also available as a passenger van (with seating up to 15 passengers - depending on the model). Later in 2008 the E85 Flexfuel Vortec 5.3L V8 also was offered to empower the 2008 Express 1500 Work Van and Passenger Van, after Duramax 6.6L Diesel engine added in 2006 (as option). Table of contents:
* Panel Identification
* Radiator Support Assembly
The radiator support assembly is made of a composite material (SMC) to reduce weight and simplify installation procedures. The radiator support bolts on and is positioned by tabs which are located into holes in the front-end lower tie bar . A steel reinforcement extends across the upper portion. This reinforcement is part of the assembly or available separately. It is attached to the radiator support by 14 rivets.
* Front Inner Fender
The front inner fender may be serviced as a complete component.
However, replacement at the factory seams requires the removal of the outer door frame panel. If the damage is limited to the front portion of the inner fender, sectioning is recommended.
* Door Service
The doors are serviced as complete assemblies, or the outer door panels may be serviced separately. Use conventional service procedures when repairing the doors. The sliding side door features bolt-on hinges, while the front doors, the 60/40 side doors, and the rear doors all feature weld on hinges. All side doors have HSLA door beams.
* Door Frame Opening
When sectioning the door frame opening in areas where there is no inner reinforcement, a 100mm backing plate must be used 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.
* Roof Panel
The roof panel consists of a single layer outer panel. The original panel is removed by cutting the panel to leave the side weld flanges attached at the “drip rail.” The service panel is not modified for installation other than drilling holes for plug welding. These procedures have been developed to simplify roof panel replacement
* Quarter Panel
The quarter panel service part is supplied as a complete panel and should be replaced as a complete panel only in the event the roof panel and upper side rail are to be replaced.
Sectioning procedures have been developed to allow the replacement of the quarter panel without the removal of the roof panel
* Rear Outer Wheelhouse
Rear outer wheelhouse sectioning procedures have been developed to simplify repair when damage is limited to the outer wheelhouse. In the event the inner wheelhouse is to be replaced, install outer wheelhouse service panel at factory seams
* Rear Door Hinge Pillar
The rear door hinge pillar service part is serviced as an assembly, which consists of the door hinge pillar outer panel and the inner anchor plate reinforcement. The reinforcement includes weld nuts for attaching the rear door bolt-on hinges.
* Floor Rear Extension
The floor rear extension panel is serviced as a single component. The reinforcement structure for the floor panel is a separate part and can only be serviced separately. In most cases, this reinforcement will need to be replaced in the event the floor panel extension is to be replaced
* Magnesium Instrument Panel Support
This component is a one-piece, die-cast magnesium instrument panel support.
It functions as a structural cross-vehicle beam, air-bag support, instrument panel carrier, steering column mounting bracket, and consolidates as many as thirty different steel and plastic components
* Body Dimensions
G Van Body Side
G Van Rear Floor Reinforcement
G Van Rear Door Hinge Pillar
G Van I/P Carrier Mounting Holes
* Frame Dimensions
The redesigned frame is fully boxed with welded joints which provide improved ride quality and greater stability. The body is attached to the frame with six body mounts which are designed to isolate powertrain noise and vibration from the passenger compartment.
* Appendix: Specifications
This manual is available FREE at GM Goodwrench website, we merely collect the information, we are neither affiliated with the author(s), the website and GM brand nor responsible for its content and change of content.
Download Free 1996-2008 GMC Savana/Chevy Express Collision Body Repair Issues Manual.pdf (32 pages pdf file, 1.3 MB).
READ MORE - Download Free 1996-2008 GMC Savana/Chevy Express Collision Body Repair Issues Manual.pdf
* Panel Identification
* Radiator Support Assembly
The radiator support assembly is made of a composite material (SMC) to reduce weight and simplify installation procedures. The radiator support bolts on and is positioned by tabs which are located into holes in the front-end lower tie bar . A steel reinforcement extends across the upper portion. This reinforcement is part of the assembly or available separately. It is attached to the radiator support by 14 rivets.
* Front Inner Fender
The front inner fender may be serviced as a complete component.
However, replacement at the factory seams requires the removal of the outer door frame panel. If the damage is limited to the front portion of the inner fender, sectioning is recommended.
* Door Service
The doors are serviced as complete assemblies, or the outer door panels may be serviced separately. Use conventional service procedures when repairing the doors. The sliding side door features bolt-on hinges, while the front doors, the 60/40 side doors, and the rear doors all feature weld on hinges. All side doors have HSLA door beams.
* Door Frame Opening
When sectioning the door frame opening in areas where there is no inner reinforcement, a 100mm backing plate must be used 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.
* Roof Panel
The roof panel consists of a single layer outer panel. The original panel is removed by cutting the panel to leave the side weld flanges attached at the “drip rail.” The service panel is not modified for installation other than drilling holes for plug welding. These procedures have been developed to simplify roof panel replacement
* Quarter Panel
The quarter panel service part is supplied as a complete panel and should be replaced as a complete panel only in the event the roof panel and upper side rail are to be replaced.
Sectioning procedures have been developed to allow the replacement of the quarter panel without the removal of the roof panel
* Rear Outer Wheelhouse
Rear outer wheelhouse sectioning procedures have been developed to simplify repair when damage is limited to the outer wheelhouse. In the event the inner wheelhouse is to be replaced, install outer wheelhouse service panel at factory seams
* Rear Door Hinge Pillar
The rear door hinge pillar service part is serviced as an assembly, which consists of the door hinge pillar outer panel and the inner anchor plate reinforcement. The reinforcement includes weld nuts for attaching the rear door bolt-on hinges.
* Floor Rear Extension
The floor rear extension panel is serviced as a single component. The reinforcement structure for the floor panel is a separate part and can only be serviced separately. In most cases, this reinforcement will need to be replaced in the event the floor panel extension is to be replaced
* Magnesium Instrument Panel Support
This component is a one-piece, die-cast magnesium instrument panel support.
It functions as a structural cross-vehicle beam, air-bag support, instrument panel carrier, steering column mounting bracket, and consolidates as many as thirty different steel and plastic components
* Body Dimensions
G Van Body Side
G Van Rear Floor Reinforcement
G Van Rear Door Hinge Pillar
G Van I/P Carrier Mounting Holes
* Frame Dimensions
The redesigned frame is fully boxed with welded joints which provide improved ride quality and greater stability. The body is attached to the frame with six body mounts which are designed to isolate powertrain noise and vibration from the passenger compartment.
* Appendix: Specifications
This manual is available FREE at GM Goodwrench website, we merely collect the information, we are neither affiliated with the author(s), the website and GM brand nor responsible for its content and change of content.
Download Free 1996-2008 GMC Savana/Chevy Express Collision Body Repair Issues Manual.pdf (32 pages pdf file, 1.3 MB).
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