K 2500 Yukon 4WD V8-6.0L VIN U (2000)
3. Lightly hand-sand the existing body hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door (Fig.
4-31).
IMPORTANT: Punch the center of the weld so that as much of the weld is removed during the drilling as possible.
4. Center punch each of the four weld marks on the original hinge base.
IMPORTANT: Do not drill into the door.
5. Drill through hinge base only at the punch location. Use a 13 mm (1/2 in) rotabroach hole saw, or the equivalent (Fig. 4-32).
6. Remove hinge. If necessary, use a chisel 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 door during the drilling or the removal.
2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate.
3. Position the service hinge within the scribe marks on the door.
4. Center punch each hole location on the door according to the service hinge.
5. Drill a 3 mm (1/8 in) pilot hole at each center punch location.
