2002-2004 Chevrolet Trail Blazer, GMC Envoy, Oldsmobile Bravada Body Repair Manual

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2002 S/T Sport Utility
Front Frame
The re-designed frame assembly for the new
S/T Utility is a mild, steel hydroformed frame
assembly. A front frame service section
consisting of the left and right frame ends,
body, and radiator support mounting
brackets and front connecting cross tube is
available.
If damage permits, locate and cut off the front
420mm
portion of the frame assembly (first 420 mm
(16 1/2 IN)
(16-1/2 in.) along the die mark indicators and
through the sway bar mounting brackets.
Front frame service section installation
requires replacement of the sway-bar
mounting brackets. The front and rear body
mounts, radiator support mounts, sway-bar
brackets, steering gear and transmission
cross-member can be ordered and replaced
separately.
Removal Procedure
1. Remove all of the related panels and
components including the front bumper
assembly and the sway bar assembly.
2002 S/T Sport Utility
420mm
2. Locate the two die-marks on each frame
rail. The die marks are located 420 mm
(16-1/2 in.) rearward from each front
frame rail end on the top and bottom
side of each rail.
420mm
2002 S/T Sport Utility Vehicles 2-1

Front Frame
Removal Procedure con't

420mm
IMPORTANT: Line up the masking
tape with the point of each die mark
arrow.
3. Apply masking tape over the
die-marks and down each frame rail
side (as shown) for cut location.
IMPORTANT: The tape edge facing
the rear of the vehicle is the proper
cut location. The cut location is not
to exceed 420 mm (16-1/2 in.) of the
front frame section.
4. Cut each frame rail at the rear edge
of the tape line and through the
sway bar bracket using a
reciprocating saw or equivalent
tool, as shown.
5. Cut the sway bar bracket in half.
—continued
2-2 2002 S/T Sport Utility Vehicles

Front Frame
Removal Procedure con't

6. Remove the damaged frame section.
IMPORTANT: Do not damage the
sway bar bracket attaching surfaces.
7. Remove and discard the remaining
sway bar brackets attached to the
undamaged portion of the frame
using a cut-off wheel or equivalent
tool.
2002 S/T Sport Utility Vehicles 2-3

Front Frame
Installation Procedure
45
1. Grind to taper existing frame rail
seam at 45 degree angle.
2. Prepare all of the attaching surfaces
as necessary.
3. Apply a weld-thru primer to all
welded surfaces.
4. Position the service frame section
to the existing frame and clamp in
place.
IMPORTANT: Check the frame
measurements three-dimensionally to
ensure proper position of the service
frame.
5. Continuous-weld the upper and
lower horizontal joints from corner
to corner.
IMPORTANT: Check the frame
measurements three-dimensionally to
ensure proper position of the service
frame.
6. Continuous-weld the inner and
outer vertical joints from corner to
corner.
—continued
2-4 2002 S/T Sport Utility Vehicles

Front Frame
Installation Procedure con’t

7. Position the new sway bar brackets
and clamp in place.
IMPORTANT: Check the frame
measurements three-dimensionally to
ensure proper position of the sway
bar brackets.
8. Continuous-weld the sway bar
bracket in place as noted from the
original parts.
9. Install all of the related panels and
components.
2002 S/T Sport Utility Vehicles 2-5

Radiator Support
Assembly
The radiator support assembly is made from
2
mild steel hydroformed tube which is welded
1
to the front structure. The Radiator Support
Assembly is serviced as a complete assembly.
2
The bolt-on portion of the upper tie bar (1) as
well as the left and the right fascia support
brackets (2) are a part of the radiator
assembly. If the damage is limited to these
parts, they can be ordered and replaced
individually. Replacement of the radiator
3
support assembly requires removal of the
upper fender rails. Upper fender rail service
extensions (3) are included with the radiator
support assembly for efficient installation. If
the damage permits, locate and cut off the
front portion of the upper rails along the die
mark indicators and install the replacement
upper fender rail service extensions. This
procedure must be performed on both sides
of the vehicle. Left side only is shown.
Removal Procedure
1. Remove all of the related panels and
components.
2. Restore as much of the damage as
possible back to factory specifications.
3. Note the location and remove the
following as necessary:
• Sealers
• Sound deadeners
• Anti-corrosion materials
4. Locate the two die-mark indicators on
the upper fender rail.
—continued
2-6 2002 S/T Sport Utility Vehicles

Radiator Support Assembly
Removal Procedure con't

IMPORTANT: The edge of the
masking tape must line up with the
point of each die-mark arrow.
5. Apply the masking tape for the cut
location over the die-marks and
across the top of the upper rail.
IMPORTANT: The tape edge facing
the front of the vehicle is the proper
cut location.
6. Cut the upper fender rail along the
front edge of the tape line.
7. Locate and drill out all of the
factory welds in the upper fender
rail in front of the cut location.
8. If necessary, use a chisel in order to
separate the upper fender rail
extension from the Radiator
Support.
—continued
2002 S/T Sport Utility Vehicles 2-7

Radiator Support Assembly
Removal Procedure con't

9. Remove the upper fender rail
extension.
10. Locate and drill out all of the
factory welds in the upper
wheelhouse area.
11. Locate and drill out all of the
factory welds along the wheelhouse
extension.
—continued
2-8 2002 S/T Sport Utility Vehicles

Radiator Support Assembly
Removal Procedure con't

12. If necessary, use a chisel in order to
separate the Radiator Support from
the vehicle.
13. Remove the damaged Radiator
Support.
2002 S/T Sport Utility Vehicles 2-9

Radiator Support
Assembly
Installation Procedure
IMPORTANT: In any area damaged
beyond recognition, space the plug weld
holes every 40 mm (1-1/2 in.) apart.
1. Prepare all of the attachment surfaces
as necessary.
2. Apply a weld-thru primer to all of the
bare metal surfaces.
3. Position and align the radiator support
using three-dimensional measuring
equipment.
4. Plug weld accordingly with frequent
measurements to ensure proper
positioning.
5. Position and align the upper fender
rail extension using three-dimensional
measuring equipment.
—continued
2-10 2002 S/T Sport Utility Vehicles