K 3500 Truck 4WD V8-6.6L DSL Turbo VIN 1 (2001)
Rear Door Hinge: Service and Repair
Hinge Replacement - Rear Door - Body Side
REMOVAL PROCEDURE
1. Remove all of the related panels and components.
2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar.
3. 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.
IMPORTANT: Punch the center of the weld so that as much of the weld as possible is removed during the drilling.
4. Center punch each of the 4 weld marks on the original hinge.
IMPORTANT: Do not drill into the hinge pillar.
5. Drill through the hinge only at each 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 pillar.
7. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge.
INSTALLATION PROCEDURE
