GM 19354128
Hinge Assembly, Passenger Side

The process of changing a rear door hinge commences with visual inspection followed by revitalizing factory standards of the damaged areas before proceeding. All panels that concern the hinge need removal along with elimination of any excess sealant from the hinge region. Mark down the hinge location on the hinge pillar and drill out all needed factory welding points found inside the hinge access panel. Gaining access to the hinge's back with the access door removed enables drilling the welds at their center using a 13 mm (1/2 in) drill bit. A chisel may be needed to free up the pillar hinge so the technician can eliminate the hinge section. To install the service hinge properly prepare the surface of the pillar until it forms a smooth joint with both components. To determine proper products and paint usage it is essential to refer to GM 4901MD-99 Refinish Manual before refinishing while avoiding any paint system mixing according to paint manufacturer guidance. The entire surface area of the hinge mounting requires moistening with approved anti-corrosion primer followed by full-body caulk application. Fasten the service hinge into the marked area of the pillar and follow up by tightening fastener bolts to 25 N.m (18 lb ft). Refinish all metal surfaces when needed before installing all related panels with their components.

The process of replacing the rear side door hinge begins by removing the door from the body before deleting extra sealer near the hinge. Begin by discarding the lock-pillar trim panel. After this step both the door and body pillar hinge locations should be scribbled down. You should center punch each weld mark on the original hinge to guarantee safe drilling during removal. Drill a 0.12 inches aircraft pilot hole through welds until it reaches the hinge base depth, utilize this narrow opening to drill a 0.51 inches hole through the base. A chisel should be used to separate the hinge from the door pillar while working between them. The hinge installation requires inserting bolt-on service replacements within pre-made scribe marks followed by center punching bolt hole positions then drilling a 13.0 mm (0.51 in) hinge attaching aperture in three sequential steps for exact hinge placement. File or similar instruments should prepare the replacement hinge surfaces before sealing the mating hinge contacts with medium-bodied sealer. I must install the hinges alongside the backing plate with the bolts by setting the hinges and pillar or door into correct positions while passing bolts through holes before screwing the nuts. Secure the nuts at a torque of 35 N.m (26 lb ft). The door must be reinstalled into the body after which the lock-pillar trim panel must be installed followed by door adjustment and application of sealer around the hinges.

Drive a chisel between the hinge and the door pillar.

A 13 mm (1/2 in) rotabroach hole saw.

Clean and prepare surfaces for refinishing, apply sealers, and reinstall and align all related panels and components.

Remove all related panels and components.

Punch the center of each weld for accurate drilling.