Front door hinge — on the door (Chevrolet Tahoe 2)

Removal

1. Remove all hinge related panels and parts.

2. Remove excess sealant around the hinge and use a scriber to draw the outline of the hinge installation on the rack.

3. Using 100 mesh or finer sandpaper, sand the hinge surface until the four weld spots are exposed.



4. Use a center punch to mark the center of the welding points.

5. Using a countersink (3) with a diameter of 13 mm, drill out the welding points in the base of the hinge (2).

Caution: Do not drill into the door frame (1).

6. Remove the hinge. If necessary, knock the hinge off with a chisel.

7. Remove any welding residue from the door frame.

Installation

1. Repair any damage to the rack caused by removing the hinge.



2. Place the new hinge onto the post using the marks made before removing the old hinge.

3. Mark the centers of the loop holes.

4. Using a 3mm drill, make pilot holes in the frame.

5. Using a 11.5mm drill bit, make the final holes in the frame.

Note: The drill diameter must be exactly 11.5 mm.

6. Clean the hinge seat.

7. Apply anti-corrosion primer to the seat.

8. Clean the area for installing the reinforcement plate on the back side of the door frame.

9. Apply sealant to the hinge and reinforcement plate seats.

10. Align the hinge (1) and reinforcement plate (4) with the holes in the door frame (2) and install the bolts (3). Tighten the bolts. Tightening torque 25 N·m.



11. If necessary, paint the new hinge.

12. Reinstall the removed panels and parts.