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 the door from the body. Refer to appropriate service manual.
Remove any excess sealer surrounding the hinge and scribe the location of the hinge on the body.
Lightly hand-sand existing body hinge with 100 grit or finer sandpaper to locate each weld attaching hinge to door.

Fig 1: Sanding Rear Side Access Door Hinge

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Original punch marks may not necessarily indicate the center of the welds.

Center punch each of the 4 weld marks on the original hinge base. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible.

IMPORTANT: Do not drill into the hinge pillar (3). Drill through hinge (2) only. If necessary, use a chisel to separate the hinge from pillar.

At each punch location, drill through hinge base only using a 13 mm (1/2 in) rotabroach hole saw (4), or equivalent.
Remove the hinge from the pillar (3).

Fig 2: Drilling Through Hinge Base

Courtesy of GENERAL MOTORS CORP.

Remove all remaining weld from the pillar surface to ensure a flush fit of service hinge.