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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1263 (Body Rear End) >> Repair Instructions >> Hinge Replacement - Rear Door >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Safari and 2002 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 tail lamp. Refer to TAIL LAMP REPLACEMENT in Lighting Systems.
  3. Remove the tail lamp filler panel.
  4. Remove the trim panel. Refer to TRIM PANEL REPLACEMENT -- DOOR in Doors.
    1. Scribe an outline of the hinge halves on the door (2) and the body (1).
    2. Use the template provided with the service hinge in order to center punch the existing welds.
    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. 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.
    7. Fig 1: Identifying Rear Door Hinge Components
    G02507108Courtesy of GENERAL MOTORS CORP.
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