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3-18 2002 Avalanche
Front Door-Side
Hinge Replacement
Removal Procedure
1. Remove related panels and
components.
2. Remove any excess sealer surrounding
the hinge and scribe the location of
the hinge on the door.
3. Lightly hand-sand the existing body
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 is
removed during the drilling as possible.
4. Center punch each of the four weld
marks on the original hinge base.
IMPORTANT: Do not drill into the
door.
5. Drill through hinge base only at the
punch location. Use a 13 mm (1/2␣ in.)
rotabroach hole saw, or the equivalent.
6. Remove hinge. If necessary, use a
chisel 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.
13mm (1/2 inch)
Rotabroach Bit
Hinge
Door
Hinge Reinforcement
Typical Mig Weld
Drill through hinge only