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2002 Avalanche 3-23
Rear Door-Side
Hinge Replacement
Removal Procedure
1. Remove related panel and
components.
2. Remove any excess sealer
surrounding the existing hinge and
scribe the location of the hinge on
the door.
3. Lightly hand-sand the existing door
hinge with 100 grit or finer
sandpaper in order to locate the
four 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 4 weld
marks on the original hinge base.
IMPORTANT: Do not drill into the
door.
5. Drill through the hinge base only at
the punch location. Use a 13␣ mm
(1/2␣ in.) rotabroach hole saw or the
equivalent.
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.
HINGE
PILLAR
13 MM (1/2 IN)
ROTABROACH BIT
HINGE REINFORCEMENT
TYPICAL MIG WELD
DRILL THROUGH HINGE ONLY