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Home >> Chevrolet >> 2002 >> Astro Van Passenger, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 825 (Body Rear End) >> Repair Instructions >> Hinge Replacement - Rear Door >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Safari and 2003 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the door from the vehicle. Refer to DOOR REPLACEMENT - REAR (CARGO DOORS)  or DOOR REPLACEMENT - REAR (E54)  .
  2. Remove the taillamp. Refer to TAIL LAMP REPLACEMENT .
  3. Remove the taillamp filler panel.
  4. Remove the trim panel: Refer to TRIM PANEL REPLACEMENT - DOOR .
    1. 4.1. Scribe an outline of the hinge halves on the door (2) and the body (1).
    2. 4.2. Use the template provided with the service hinge in order to center punch the existing welds.
    3. 4.3. Drill a 3.0 mm (1/8 in) pilot hole completely through the following components at the punch marks:
      • Hinge
      • Frame
      • Reinforcement
      • Gusset
    4. 4.4. Use the pilot holes as guides in order to drill a 13.0 mm (1/2 in) hole through the following components at the punch marks:
      • Hinge
      • Frame
      • Reinforcement
      • Gusset
  5. Drive a chisel between the hinge and the door frame if any additional weld holds the hinge to the frame in order to remove the hinge halves.
  6. Remove any additional weld on the door or the body side frame. This step may include using a grinder in order to remove any remaining weld.
    Fig 1: Removing Rear Door Hinge Pins
    G01567331Courtesy of GENERAL MOTORS CORP.
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