Yukon 4WD V8-6.5L DSL Turbo VIN S (1997)
7.
Cut out the appropriate template (see Figure 2) and position it on the hinge as indicated. Center punch the location points of the bolt on fasteners.
8.
Drill the center points of the bolt on fasteners using a 1/8 inch (3 mm) drill. Drill completely through the hinge, inner door panel sheet metal, and
the interior hinge reinforcement sheet metal for future reference.
9.
Drill the center points of the spot weld locations using a 1/8 inch (3 mm) drill only as deep as the hinge material thickness. Do not drill these holes
through the inner door panel sheet metal.
10.
Drill the center points of the spot welds using a 1/2 inch (13 mm) drill. It will be necessary to drill until the tip of the drill penetrates the door sheet
metal to allow a full 1/2 inch (13 mm) diameter of material to be removed from the hinge.
11.
Use a chisel to separate the hinge from the door if necessary. Care should be taken to minimize damage to the door.
12.
Drill the bolt on fastener locations identified in step 8 using a 1/2 inch (13 mm) drill through the inner door sheet metal and hinge reinforcement
sheet metal.
13.
Prepare the door surface to insure the hinge area is flat and free of burrs.
