Sierra 1500 2WD V8-5.3L Hybrid (2004)
Front Door Hinge: Service and Repair
Hinge Replacement - Front Door - Door Side
Hinge Replacement - Front 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 door.
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 four weld marks on the original hinge base.
Important: Do not drill into the door (1).
5. Drill through the hinge base (2) only, 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 weld from the door surface in order to ensure a flush fit of the service hinge.
Installation Procedure
1. Repair any damage done to the door during the drilling or the removal of the hinge.
2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate.
