GM 15080226
Hinge

Begin repair of rear cargo door hinge by examining factory-harmful damages then restoring them to original factory state. All panels and components connected to the hinge need removal before you can eliminate any extra sealant present around the hinge area. Delimitate the position of the hinge on the hinge pillar before drilling all factory welds needing removal from the hinge access panel. You must open the access door to see the hinge back side where you should drill the welds using a 13 mm (1/2 in) drill bit. You should use a chisel to break the pillar-ted chain from the pillar prior to removing the hinge altogether. Before mounting the service hinge users need to make sure that both pillar surfaces receive proper cleaning and preparation to ensure a uniform fit of the fasteners and hinge. The GM 4901 MD-99 Refinish Manual should be consulted for proper product recommendations and paint system combination should be avoided according to the paint manufacturer guidelines. Place anti-corrosion primers approved by the manufacturer and full-body caulk onto all sections of the mounting surface. Irrespective of the scribe marks on the pillar install the service hinge then tighten its fasteners to 25 N.m (18 lb ft). Finish the metal surfaces if needed before repositioning and mounting all linked components and panels.

Start by removing door panels while also removing components attached to the hinge. After removing an excess amount of sealer you should write the location of the hinge on the pillar. Sand the existing hinge lightly with 100 grit or finer sandpaper starting from its attachment points to the pillar while puncturing the welds in their centers for simple drilling later. Punch the centers of each weld mark on the original hinge but avoid drilling into the door. Use a 13 mm (1/2 in) rotabroach hole saw as well as other comparable tools to drill through the hinge at the punch locations while also employing a chisel if needed to detach the hinge from the door surface. A smooth surface must form on the door because all welding remnants need removal before the service hinge can utilize it. The door must be fixed from all drilling and hinge removal damage before cleaning the backing plate surfaces and preparing them for smooth mounting. The door service hinge needs to be placed inside the scribe marks and then each hole location needs to be center punched before drilling 3 mm (1/8 in) pilot holes at every mark using a drill bit of exact size. Clean up all exposed metal surfaces before applying approved anti-corrosion primer to them. After drilling 11.5 mm (29/64 inches) holes at the stud positions and creating pilot holes, treat all surfaces with anti-corrosion products. Apply full-bodied caulk across the entire hinge mounting surface before aligning the hinge together with the backing plate with the door holes. Afterward install the bolts and tighten the pillar nuts to 25 N.m (18 lb ft). The technician will finish the workspace by applying sealers followed by refinishing procedures before accomplishing component and panel installation.

Use a 13 mm (1/2 in) rotabroach hole saw to drill through the hinge base at each punch location.

Begin by removing all related panels and components.

Clean off any remaining weld to ensure a flush fit for the new hinge and repair any damage to the door from the removal process.