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Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove all of the related panels and components.
  2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar.
  3. 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.

    4. Fig 1: Lightly Hand-Sanding Existing Hinge
    G01713979Courtesy of GENERAL MOTORS CORP.
  4. Center punch each of the four weld marks on the original hinge base.

    Important:  Do not drill into the door (1).

  5. Drill through the hinge base (2) only, at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw (3) or equivalent.
    6. Fig 2: Using A Rotabroach Hole Saw
    G01713980Courtesy of GENERAL MOTORS CORP.
  6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the door.
  7. Remove all of the remaining weld from the door surface in order to ensure a flush fit of the service hinge.
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