K 3500 Truck 4WD V8-6.6L DSL Turbo VIN 1 (2001)
Rear Door Hinge: Service and Repair
Hinge Replacement - Rear Door - Door 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: It is critical to 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 four weld marks on the original hinge.
IMPORTANT: Do not drill into the door (1).
5. Drill through the hinge (2), at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw (3) or 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 welds from the door surface in order to ensure a flush fit of the service hinge.
INSTALLATION PROCEDURE
