I have an AT4x
View attachment 9884and had the same thing happen to me last week. The thing flew off and smacked my windshield and bounced off the roof, going about 50 mph; thankfully, no one was right behind me. The damage to the truck was minimized because I previously had the piece wrapped, as I didn't care much for the bronzy look next to the tan paint color, so it didn't scratch the truck. Once I got home and realized what happened, I went back and retrieved it from the side of the road. As mentioned above, all the clips were sheared off completely (see first photo) almost uniformly. I went to the dealer and was told they have to order the entire grille, which can take up to 1-2 months as they are on backorder. This didn't make sense to me, so I asked my service advisor (a really nice guy) to let me go into the shop to talk to the tech to ask him some questions. The tech told me that it is possible to put the new upper cover on without removing the lower grille but that GM doesn't just sell the top piece by itself (which is stupid!), as others on this tread had mentioned. He showed me how to get the remains of the clips out of the slots with a screwdriver; the end tabs are simply screwed on. So I ordered a replacement piece (from ebay for about $80, but I purposely ordered a colored one this time as I think the plastic might be a little stronger.
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Here is my theory of what is happening to our trucks: First off, as mentioned, this is absolutely a factory defect that GM is ignoring; as the tech mentioned, he has seen several trucks come in with the same issue. I think that this is happening on all the trucks but more often with the AT4, AT4x, and the Denali, basically any of the units with the Chrome, Black Chrome, or bronze trim. These versions appear to be made with a thinner and, unfortunately for us, weaker material than the ones that are simply painted. I think what is happening is multiple things: any debris hits it (mine got struck by a rock), you frequent a car wash (I probably go once a week as I have a membership), or you or either your tech/mechanic leans on it while working in the engine bay, the tabs are being weakened and broken one or two at a time. Once enough of the tabs are broken, and you get enough wind lift, the rest of them snap, and the thing goes flying off!
My suggestion: is to only purchase the painted ones if you want to do a temporary fix while your new grille comes in. You can have it wrapped in gloss black or any other color or texture at any good tint shop, and it may even look better. When my new grille comes in, I plan to very carefully add wire reinforcements with a plastic welding gun on each of the tabs (which, by the way, is what GM should be doing!) I really like my AT4x overall, but come on, GM, the build quality on these overpriced trucks is unacceptable! The list of issues keeps growing! I recently discovered an annoying increasing creaking noise coming from my driver's seat (details on that will be on another thread!)
BTW: the tech also gave me a nugget regarding our engines (both the 5.3 & 6.2): He warned that we should not follow the engine life indicator in the dash (I had brought mine in early because of the grille issue); instead, get the oil changed at 40% or 50% life left mark or every 3500-4000 miles. Also, check your oil level between oil changes, as both engines are notorious for burning oil. He said that over half of the engine replacements he has done could have been avoided if the owners had done this. I asked him why GM doesn't simply change or update the oil indicator software in our trucks (and the new ones they are selling) and simply give everyone several free oil changes to compensate, as that would be cheaper than replacing all these engines (which is why my dealer didn't have any loaner vehicles when I came in), and he said they don't want to raise the cost of ownership compared to their competitors! I'm thinking that this is my first and last GM product! (SMH)