Removal Procedure
WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 Chevrolet Tahoe, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
- Remove all of the related panels and components.
- Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar.
- Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door.
- Center punch each of the four weld marks on the original hinge base.
- Drill through the hinge base (2) only, at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw (3) or equivalent.
- Remove the hinge. If necessary, use a chisel in order to separate the hinge from the door.
- Remove all of the remaining weld from the door surface in order to ensure a flush fit of the service hinge.
IMPORTANT:
Punch the center of the weld so that as much of the weld as possible is removed during the drilling.
IMPORTANT:
Do not drill into the door (1).