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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1419 (Door System, Mirror System & Window System) >> Repair Instructions >> Hinge Replacement - Front 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. Refer to DOOR REPLACEMENT - FRONT  .
  2. Remove the sealer from around the edge of the hinge.
    3. Fig 1: Identifying Front Door Hinge Sealer Location
    G02506728Courtesy of GENERAL MOTORS CORP.
  3. Scribe the location of the existing hinges on the door and the body pillar (1).
  4. Center punch each of the original welds on each hinge base (3).
    5. Fig 2: Removing Original Front Door Hinge Welds
    G02506729Courtesy of GENERAL MOTORS CORP.
  5. Drill a 3.0 mm (1/8 in) pilot hole completely through each weld at each punch mark. Drill through the hinge base ONLY. DO NOT drill through the door or the body pillar.
  6. Drill a 13.0 mm (1/2 in) hole through the hinge base. Use the 3.0 mm (1/8 in) hole as a pilot. DO NOT drill through the door or the body pillar.
  7. Use a chisel in order to separate any remaining weld attaching the hinge to the door or the body pillar.
  8. Remove the hinge from the door or the body pillar.
    9. Fig 3: Removing Original Front Door Hinge
    G02506730Courtesy of GENERAL MOTORS CORP.
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