2000 GMC Savana 1500 Door Hinge

You can remove the front door trim panel, the door, and the door side hinges.

You can remove the door, the wire harness, and the body side hinges.

You can remove the door that requires hinge replacement, and interior trim at the pillar. Cut the production body side door hinge. Use a reciprocating saw to gain access for drilling. Tape around the periphery of the body side hinges to mark the hinge location. Place the service backing plate on the production hinge surface and mark the 3-hole pattern. Center punch the marked 3-hole pattern. Drill pilot holes with a 3 mm (1/8 in) drill bit through the production hinge and body pillar. Protect the interior of the vehicle and the adjacent door interior from potential metal grindings. Lightly sand the body side hinge surface to locate the 3 production welds, and look for a witness mark. Center punch the 3 production welds for locating the drill bit. Using the center punch locations, use a 19 mm (3/4 inch) rota-broach to drill out the remainder of the production hinge without drilling through the body side hinge pillar. Cut the hinge weld nuggets off. Grind the pillar hinge mating surface flush. Use the pilot holes drilled to center the drill bit, and drill 13 mm (33/64 in) holes through the pillar.

You can Deburr the holes on the inside of the hinge pillar or the door to insure the proper seating of the hinge and the backing plate. Inspect the body pillar and the door to ensure that the hinge seating zone on the body pillar or the door is flat. Paint the inner and the outer surfaces of the hinge pillar or the door at the hinge mounting zone. Coat the mating surface of the hinge with a medium-bodied sealer. Install the hinge to the body pillar or the door using the bolts and the tapping plate, the door. Apply the sealer around the hinges. Paint the hinge.

You can install the hinges to the door, and the door to the vehicle.