GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2003 🢒 GMC K Sierra - 4WD 🢒 Body and Accessories 🢒 Doors 🢒 Rear Side Access Door Hinge Replacement

Removal Procedure

    Object Number: 675806 Size: SH
  1. Remove the door from the body. Refer to appropriate service manual.
  2. Remove any excess sealer surrounding the hinge and scribe the location of the hinge on the body.
  3. Lightly hand-sand existing body hinge with 100  grit or finer sandpaper to locate each weld attaching hinge to door.

    4. Important: Original punch marks may not necessarily indicate the center of the welds.

  4. Center punch each of the 4 weld marks on the original hinge base. It is critical to punch the center of the weld so that as much of the weld is removed during drilling as possible.

    5. Object Number: 675808 Size: SH

    Important: Do not drill into the hinge pillar (3). Drill through hinge (2) only. If necessary, use a chisel to separate the hinge from pillar.

  5. At each punch location, drill through hinge base only using a 13 mm (1/2 in) rotabroach hole saw (4), or equivalent.
  6. Remove the hinge from the pillar (3).
  7. Remove all remaining weld from the pillar surface to ensure a flush fit of service hinge.

Installation Procedure

    Object Number: 675809 Size: SH
  1. Repair any damage done to the pillar during drilling or removal.
  2. Position the hinge within the scribe marks on the hinge pillar.
  3. Center punch each stud location on the pillar according to the service hinge.
  4. Drill a 3 mm (1/8 in) pilot hole at each center punch location.
  5. At the pilot hole location, drill 11.5 mm (29/64 in) hole through the pillar.

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

  6. Apply an approved anti-corrosion primer to all bare metal surfaces.

    7. Object Number: 675811 Size: SH
  7. Feed fish wire GM P/N 15017229 through the hinge, the hinge pillar and out the conduit hole in the pillar.

    8. Object Number: 675798 Size: SH
  8. Install stud GM P/N 15017230 into the end of the fish wire and pull the stud into position.
  9. Hold the stud in position with the hinge and remove the fish wire.
  10. Install nut GM P/N 11516746 on the stud and draw the stud through the pillar. This will seat the stud and prevent it from splitting.
  11. Repeat steps 7-10 on the remaining stud locations.
  12. Remove the nuts and hinge.
  13. Apply a full-bodied caulk to the entire hinge mounting surface to ensure a proper seal.
  14. Align the hinge and install using fasteners supplied.
  15. Torque the hinge bolts to 25 N·m (18 ft lb).

    16. Object Number: 675800 Size: SH
  16. Modify the door side hinge lower extensions (1), if installing the original access door without a door side service hinge or a used access door.

    17. Object Number: 675804 Size: SH
  17. Trim hinge extensions (1) so they maintain a wall thickness of 2 mm between the end of the extensions and the body side hinge nuts (3).
  18. Measure and maintain a wall thickness of 2 mm around the hole at the end of the extension (4).

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

  19. Clean and prepare all surfaces.
  20. Refinish as necessary.
  21. Install and align all related panels and components.