Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. 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.

IMPORTANT: Punch the center of the weld so that as much of the weld as possible is removed during the drilling.

Center punch each of the 4 weld marks on the original hinge.

Fig 1: Sanding Hinge & Punching Weld Marks

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Do not drill into the hinge pillar.

Drill through the hinge only at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or the equivalent.

Fig 2: Drilling Through Hinge

Courtesy of GENERAL MOTORS CORP.

Remove the hinge. If necessary, use a chisel in order to separate the hinge from the pillar.
Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge.