Front Door Hinge: Service and Repair

Hinge Replacement - Front Door - Body Side

Removal Procedure

1. Remove the door from the vehicle. Refer to Door Replacement - Front (Service and Repair) .
2. Remove all related panels and components.
3. Visually inspect the damaged areas.
4. Restore as much of the damage as possible to factory specifications.
5. Remove the sealers, sound deadeners, and anticorrosion materials as necessary. Refer to Anti-Corrosion Treatment and Repair () in Paint/Coatings.




6. Locate all factory welds.
Important: Note the location of the welds for the installation of the body side door hinge.




Important: Do not cut into the door opening frame panel.


7. Carefully grind the weld from around the body side door hinge.
8. Remove the hinge and grind any remaining weld from the pillar surface in order to ensure a flush fit of the service hinge.



Installation Procedure





1. Obtain two 10 mm (0.40 in) wood spacers (1).
2. Tape the spacers in the positions shown near the dimples in the flange of the rocker panel.
3. Prepare all mating surfaces as necessary.
4. Apply 3M Weld-Thru Coating P/N 05916 or equivalent, to all mating surfaces.
5. Install the body side door hinge straps and the hinge pins to the door assembly . Refer to Door Replacement - Front (Service and Repair) .
6. With the aid of an assistant, position the door assembly to the door opening frame.

Important: Position the rear of the door approximately 3 mm (0.11 in) higher than specified to allow for the additional weight of the door hardware and trim components.


7. Adjust its position in the rear with shims as required.




8. Tack weld the upper and lower door body side hinges to the door opening frame assembly.
9. Remove the spacer blocks and shims and recheck the door alignment.
10. Complete the welding of the body side door hinge straps.
11. With the aid of an assistant, remove the door assembly from the body side door hinge straps. Refer to Door Replacement - Front (Service and Repair) .
12. Clean and prepare welded surfaces.
Important: Prior to refinishing, refer to the publication GM 4901 M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.



13. Apply an approved anti-corrosion primer.
14. Apply a smooth bead of joint sealer Lord Fusor 800/801 or equivalent around all sides of the hinge.
15. Refinish the surfaces as necessary.
16. Apply sealers and anti-corrosion materials as necessary. Refer to Anti-Corrosion Treatment and Repair () in Paint/Coatings.
17. Install the door to the vehicle. Refer to Door Replacement - Front (Service and Repair) .
18. Install all the related panels and components.