Silverado 3500 2WD V8-6.6L DSL Turbo VIN 2 (2004)
Front Door Hinge: Service and Repair
Door Hinge Replacement
Door Hinge Replacement
Body Side
REMOVE OR DISCONNECT
1. Remove door from body.
2. Visually inspect and restore as much of the damage as possible to factory specifications.
3. Lightly hand-sand existing hinge with 100 grit or finer sandpaper to locate the four welds attaching hinge to the pillar (Fig.1.12).
4. Center punch each of the four weld marks on the original hinge. It is critical to punch the center of the weld so that as much of the weld is removed
during drilling as possible.
NOTE: Do not drill into the hinge pillar -drill through hinge ONLY (Fig.1.13). If necessary, use a chisel to separate the hinge from the pillar.
5. At each punch location, drill through hinge ONLY, using a 13 mm (1/2 inch) rotabroach hole saw or equivalent. (Fig.1.13).
6. Remove all remaining weld material from pillar surface to ensure a flush fit of the service hinge.
INSTALL OR CONNECT
1. Repair any damage done to the pillar during drilling or removal.
2. Position the service template on the hinge pillar using 3M's Repositionable Adhesive (Part #6091), or equivalent.
3. Center punch each stud location on the hinge pillar according to the template.
