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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 806 (Body Rear End) >> Repair Instructions >> Hinge Replacement - Rear Cargo Door - Lower Body Side >> Removal Procedure

Removal Procedure

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  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. Remove any excess sealer surrounding the hinge.
    4. Fig 1: Removing Excess Sealer Surrounding Hinge
    G01459437Courtesy of GENERAL MOTORS CORP.
  4. Scribe the location of the hinge on the hinge pillar.
    5. Fig 2: Scribing Location Of Hinge On Hinge Pillar
    G01459438Courtesy 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 3: Sanding Existing Hinge
    G01459439Courtesy of GENERAL MOTORS CORP.
  6. Center punch each of the 4 weld marks on the original hinge.
    7. Fig 4: Punching Of Weld Marks On Original Hinge
    G01459440Courtesy 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.
    Fig 5: Drilling Out Factory Welds In Rear Body Opening Lower Filler
    G01459441Courtesy 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. Fig 6: Prying Back Filler Panel
    G01459442Courtesy of GENERAL MOTORS CORP.
  9. Remove rear body opening lower filler. If necessary, use a chisel in order to separate the filler from the opening.
  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 7: Drilling Through Hinge
    G01459443Courtesy 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 8: Removing Hinge
    G01459444Courtesy 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.
    14. Fig 9: Removing Remaining Weld
    G01459445Courtesy of GENERAL MOTORS CORP.
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