GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Chevy C Cab/Chassis HD (GMT 400) 🢒 Body 🢒 Doors 🢒 Front Side Door Hinge Replacement - Door Side

Removal Procedure

    Object Number: 898457 Size: SH
  1. Remove the door. Refer to Front Side Door Replacement .
  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.

    4. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling. Original punch marks may not necessarily indicate the center of the welds.

  4. Center punch each of the four weld marks on the original hinge base.

    5. Object Number: 383434 Size: SH

    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

    Object Number: 383439 Size: SH
  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.
  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.

    6. Important: Drill bit must be exact size.

  6. Drill an 11.5 mm (29/64 in) hole at the pilot locations.
  7. Clean and prepare all of the bare metal surfaces.

    8. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

  8. Apply approved anti-corrosion primer.
  9. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal.

    10. Object Number: 898458 Size: SH
  10. Align the service hinge (2) to the door (3) and install the fasteners (1).
  11. Apply the sealers.
  12. Refinish the metal surfaces as necessary.

    13. Notice: Refer to Fastener Notice in the Preface section.

  13. Install the door and align all of the related panels and the components.

    14. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).