C 3500 Truck 2WD V8-6.6L DSL Turbo VIN 1 (2002)
Rear Door Hinge: Service and Repair
Rear Side Access Door Hinge Replacement
Rear Side Access Door Hinge Replacement
Removal Procedure
1. Remove the door from the body. Refer to appropriate service manual.
2. Remove any excess sealer surrounding the hinge and scribe the location of the hinge on the body.
3. Lightly hand-sand existing body hinge with 100 grit or finer sandpaper to locate each weld attaching hinge to door.
Important: Original punch marks may not necessarily indicate the center of the welds.
4. Center punch each of the 4 weld marks on the original hinge base. It is critical to punch the center of the weld so that as much of the weld is
removed during drilling as possible.
Important: Do not drill into the hinge pillar (3). Drill through hinge (2) only. If necessary, use a chisel to separate the hinge from pillar.
5. At each punch location, drill through hinge base only using a 13 mm (1/2 in) rotabroach hole saw (4), or equivalent.
6. Remove the hinge from the pillar (3).
7. Remove all remaining weld from the pillar surface to ensure a flush fit of service hinge.
Installation Procedure
1. Repair any damage done to the pillar during drilling or removal.
2. Position the hinge within the scribe marks on the hinge pillar.
3. Center punch each stud location on the pillar according to the service hinge.
4. Drill a 3 mm (1/8 in) pilot hole at each center punch location.
