LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 631 (Body Rear End) >> Repair Instructions >> Hinge Replacement - Rear Cargo Door - Lower Body Side >> Removal Procedure

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.
  1. Visually inspect and restore as much of the damage as possible to factory specifications.
  2. Remove all of the related panels and the components.
    3. Fig 1: Removing Excess Sealer Surrounding Hinge
    GM637644Courtesy of GENERAL MOTORS CORP.
  3. Remove any excess sealer surrounding the hinge.
    4. Fig 2: Scribing Location Of Hinge On Hinge Pillar
    GM637647Courtesy of GENERAL MOTORS CORP.
  4. Scribe the location of the hinge on the hinge pillar.
    5. Fig 3: Sanding Existing Hinge
    GM637650Courtesy of GENERAL MOTORS CORP.
  5. 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 pillar.
    6. Fig 4: Center Punching Weld Marks
    GM637652Courtesy of GENERAL MOTORS CORP.
  6. Center punch each of the 4 weld marks on the original hinge.
    7. Fig 5: Drilling Out Factory Welds In Rear Body Opening Lower Filler
    GM637655Courtesy of GENERAL MOTORS CORP.
  7. Locate and drill out all necessary factory welds in the rear body opening lower filler, using 8 mm (5/16 in) spot weld remover, in order to gain access to the backside of the lower hinge.
    8. Fig 6: Removing Rear Body Opening Lower Filler
    GM637657Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Use care when removing the filler panel. The filler panel must be reinstalled.
  8. Carefully pry back the filler panel.
  9. Remove rear body opening lower filler. If necessary, use a chisel in order to separate the filler from the opening.
    10. Fig 7: Drilling Through Hinge At Punch Locations
    GM637660Courtesy of GENERAL MOTORS CORP.
  10. Drill through the hinge only at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or the equivalent.
    11. Fig 8: Separating & Removing Rear Cargo Door Hinge (Lower Body Side)
    GM637662Courtesy of GENERAL MOTORS CORP.
  11. If necessary, use a chisel in order to separate the hinge from the pillar.
  12. Remove the hinge.
    13. Fig 9: Removing Remaining Weld From Pillar Surface
    GM637664Courtesy of GENERAL MOTORS CORP.
  13. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge.
scientia non olet · About LEMON Manuals