How to Assemble the Front Bumper on a 2003 Chevy Avalanche
Long ago, in a faraway place called "The 1980s," manufacturers seemed to have unanimously agreed that plastic bumper covers looked better on everything. And trucks may have lagged a few years behind, but they too, eventually got with the aesthetic program. So, it should come as no surprise that the Avalanche -- favored as it is amongst truck enthusiasts who care about civility -- should have such impressive support from the add-on aftermarket. But, whether you're replacing your bumper for an upgrade or a repair, it all starts with getting the thing off.
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Instructions
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1
Look inside the front of the inner fenderwells, ahead of the wheel, where the fenders attach to the bumper. You'll see five set screws; remove the screws using a Phillips-head screwdriver, and pull them out.
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2
Crawl under the front of the truck, and remove the bolts that secure the bumper to the center of the radiator shroud. Pull the bumper out slightly, to ensure that it won't catch on anything as you remove it.
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3
Remove the four bolts that secure the bumper to the radiator core support mounting pads. Reach behind the bumper, and disconnect the wiring harnesses that power the fog lights, if equipped.
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4
Grasp the edge of one side of the bumper, and gently pull outward on it. The bumper's clips should pop free as you pull outward, but a flat-bladed screwdriver may help to release them if they prove stubborn. Repeat on the other side.
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5
Push down on the upper edge of the bumper to release the 14 clips that secure it to the grille. You may want to enlist the services of a helper at this point; the bumper weighs about 40 pounds, and there's no sense in damaging the existing cover if you drop it.
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6
Install in the reverse order of removal. Torque the bumper bolts to 75 foot-pounds. Torque the screws to 14 inch-pounds, and the lower bolts to 5 foot-pounds.
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Tips & Warnings
You don't actually have to remove the primary bumper support to replace the front fascia; but, it's just as easy to pull the bumper support from the back of the fascia than unbolt it from the truck after removing the fascia. It's your decision.
