Savana 2500 V8-6.6L DSL Turbo (2008)
9. Drill pilot holes with a 3 mm (1/8 in) drill bit all the way through the production hinge and body pillar.
10. Protect the interior of the vehicle and the adjacent door interior from potential metal grindings.
11. Lightly sand the body side hinge surface to locate the 3 production welds, look for witness mark.
12. Center punch the 3 production welds for locating drill bit.
13. Using the center punch locations, use a 19 mm (3/4 inch) rota-broach to drill out the remainder of the production hinge without drilling through
the body side hinge pillar.
14. Cut the hinge weld nuggets off.
15. Grind the pillar hinge mating surface flush.
16. Using the pilot holes drilled to center the drill bit, drill 13 mm (33/64 in) holes through the pillar.
Installation Procedure
