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Updating Your 1991 GMC Truck - Fresh Start

Updating Your '91 GMC Truck
By John O'Neill
Photography by John O'Neill
1991 Gmc Truck After
After
1991 Gmc Truck Before
Before
1991 Gmc Truck Upper Grille Shell
1. We began by removing the... 
   
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1991 Gmc Truck Upper Grille Shell
1. We began by removing the upper grille shell bolts on the core support.
1991 Gmc Truck Running Lights
2. Four screws secure the... 
   
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1991 Gmc Truck Running Lights
2. Four screws secure the running lights to the shell on both sides. Twist the bulbs free once the light assembly is loose.
1991 Gmc Truck Running Lights Screws
3. Once the running lights... 
   
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1991 Gmc Truck Running Lights Screws
3. Once the running lights are out of the way you can access the screws behind them.
1991 Gmc Truck Upper And Lower Screws
4. Hidden behind the grille... 
   
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1991 Gmc Truck Upper And Lower Screws
4. Hidden behind the grille are upper and lower screws that must be removed.
1991 Gmc Truck Side Marker Lights
5. Before the grille shell... 
   
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1991 Gmc Truck Side Marker Lights
5. Before the grille shell is pulled off, unplug the side marker lights.
1991 Gmc Truck Entire Grille Shell
6. The entire grille shell... 
   
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1991 Gmc Truck Entire Grille Shell
6. The entire grille shell can now be taken to the workbench.
1991 Gmc Truck Remove Bolts
7. Use a ratchet to remove... 
   
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1991 Gmc Truck Remove Bolts
7. Use a ratchet to remove the bolts that secure the front bumper to the framerails.
1991 Gmc Truck Free Bumper
8. Now that the bumper is... 
   
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1991 Gmc Truck Free Bumper
8. Now that the bumper is free, you can set it aside for target practice.
1991 Gmc Truck Reuse Bolts
9. Reuse the bolts to attach... 
   
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1991 Gmc Truck Reuse Bolts
9. Reuse the bolts to attach the front bumper to the truck.
1991 Gmc Truck Smoothie Bumper
10. The smoothie bumper from... 
   
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1991 Gmc Truck Smoothie Bumper
10. The smoothie bumper from Universal Auto already helps the front end nicely.
1991 Gmc Truck Cut Off Wheel
11. Use a cut-off wheel to... 
   
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1991 Gmc Truck Cut Off Wheel
11. Use a cut-off wheel to remove the plastic bars on the new grille to make room for the new billet piece.
1991 Gmc Truck Test Fit Billet Grille
12. Next, test-fit the billet... 
   
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1991 Gmc Truck Test Fit Billet Grille
12. Next, test-fit the billet grille into the grille shell and make sure everything matches up.
1991 Gmc Truck Three Holes
13. Once the grille is in... 
   
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1991 Gmc Truck Three Holes
13. Once the grille is in place, three holes are drilled on the top and bottom of the shell and the billet grille is secured using the provided screws.
1991 Gmc Truck Retainer Clips
14. Remove the retainer clips... 
   
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1991 Gmc Truck Retainer Clips
14. Remove the retainer clips and the top filler piece from the old shell.
1991 Gmc Truck Filler Piece
15. Using the retainer clips,... 
   
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1991 Gmc Truck Filler Piece
15. Using the retainer clips, secure the filler piece to the new grille shell.
1991 Gmc Truck Plastic Spacers
16. Pull out the plastic spacers... 
   
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1991 Gmc Truck Plastic Spacers
16. Pull out the plastic spacers from the old shell. A nut driver will help collapse the plastic clips.
1991 Gmc Truck Running Lights
17. Snap the spacers in place... 
   
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1991 Gmc Truck Running Lights
17. Snap the spacers in place on the new shell, which the running lights will later mount to.
1991 Gmc Truck Removes Bolts
18. Next, remove the bolts... 
   
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1991 Gmc Truck Removes Bolts
18. Next, remove the bolts that hold the headlight in place. Once the bucket is loose, twist the bulbs free.
1991 Gmc Truck Diamond Cut Headlights
19. The new diamond-cut headlights... 
   
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1991 Gmc Truck Diamond Cut Headlights
19. The new diamond-cut headlights and running lights from procarparts.com will help update the look of the truck. Snap the new bulbs into the stock wiring harness, then twist them into the headlight bucket.
1991 Gmc Truck Factory Bolts
20. Using the factory bolts,... 
   
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1991 Gmc Truck Factory Bolts
20. Using the factory bolts, tighten the new headlight assembly into place.
1991 Gmc Truck Clear Lenses
21. There would be no reason... 
   
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1991 Gmc Truck Clear Lenses
21. There would be no reason to leave the super-orange corners next to all our clear lenses. Remove the two 13mm speed nuts; be easy with these as you might break the tip off if you get a little over-zealous.
1991 Gmc Truck In Pro Car Wear
22. The same goes for installing... 
   
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1991 Gmc Truck In Pro Car Wear
22. The same goes for installing the new In-Pro Car Wear clear corners: Tighten them just enough.
1991 Gmc Truck Lenses
23. Now that the lenses are... 
   
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1991 Gmc Truck Lenses
23. Now that the lenses are nice and clear, they still have to blink orange, so a new set of amber bulbs is provided. Just pull the old ones straight out.
1991 Gmc Truck Place New Grille Sheet
24. Carefully position the... 
   
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1991 Gmc Truck Place New Grille Sheet
24. Carefully position the new grille shell in place and bolt it to the core support.
1991 Gmc Truck Four Torx Head Screws
25. Finally, tighten the four... 
   
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1991 Gmc Truck Four Torx Head Screws
25. Finally, tighten the four torx head screws that hold the running lights in place.
1991 Gmc Truck Front End
26. Here is the new front... 
   
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1991 Gmc Truck Front End
26. Here is the new front end complete with grille shell, billet grille, clear corners, diamond lights, and smoothie bumper. What a difference!
1991 Gmc Truck Billet Superstore
27. We had Colby at Billet... 
   
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1991 Gmc Truck Billet Superstore
27. We had Colby at Billet Superstore rip off the moldings that were cluttering up our truck. Colby recommends using a heat gun to get the molding soft enough to pry up the edge.
1991 Gmc Truck Pull Free
28. Once there is enough to... 
   
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1991 Gmc Truck Pull Free
28. Once there is enough to grab, you can pull it free from the cab.
1991 Gmc Truck Eraser
29. A 3M body eraser is used... 
   
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1991 Gmc Truck Eraser
29. A 3M body eraser is used to take off the leftover two-sided tape.
1991 Gmc Truck Fenderwell Trim
30. The fenderwell trim was... 
   
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1991 Gmc Truck Fenderwell Trim
30. The fenderwell trim was also going to look out of place, so we decided to remove it. Phillips head screws hold it on. If the screws look rusty, spray on some WD-40; the small heads could break if they're stuck.
1991 Gmc Truck Residue
31a. There will be some residue... 
   
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1991 Gmc Truck Residue
31a. There will be some residue left over from the eraser. Colby wiped it off with some M.E.K. body solvent.
1991 Gmc Truck Mek Body Solvent
31b.
1991 Gmc Truck Moldings Gone
32. Here's the truck looking... 
   
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1991 Gmc Truck Moldings Gone
32. Here's the truck looking much cleaner now that the ugly side moldings are gone.

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