Chevy Tahoe and GMC 4 Door Yukon PDF Manual

Step 5: Flare Installation (Rear)
There are three parts to each rear flare: Inner Door Part (IDP), Outer Door Part (ODP), and Rear Part. Special attention must be given to assure proper alignment of each part to the others. (A) Tape Outer Front and Rear Door Parts in position. Provide a space of 1/8” between inside edge of the Outer Door Part and inside surface of wheel well rim. See Illustration #3 – Cross Section. This space is needed to provide clearance for door operation. Confirm that all flare parts align with each other, and vehicle seams. Verify that both ODP and IDP do not interfere with door opening or closing. Trace the outside edge of each part on vehicle side using a grease pencil.

(B) Attach edge trim to the outer edge of Rear Flare and ODP using pre-applied adhesive strip. See Illustration #2. Using a clean rag, apply a coating of plastic adhesive to the area of the IDP which contacts the ODP. On your work surface lay the IDP inside the ODP and hold together for 90 seconds. Allow adhesive to set up for at least 30 minutes before attaching assembled parts to the vehicle. Read separate instructions packaged with adhesive for details on use.
(C) Using the line traced in Step 5A as a guide, secure the Rear Part to the fender using two kit-furnished drill screws at top center and lower “flat.” Install the remaining four screws at the locations shown in Illustration #2.

(D) the rear door and remove the weather stripping from the inner door edge. Using a 3/16” drill bit drill four holes through the door at locations indicated in Illustration #3.

(E) With door closed, duct tape assembled door parts to the door using line traced in Step 5A as a guide. Open the door. Using drill screws, attach door part through holes drilled in Step 5D. Take care not to strip out the plastic of the IDP.

Download 4 Door Chevy Tahoe and GMC Yukon, 40502 (Set) PDF Manual