Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 387 (DOOR SYSTEM, MIRROR SYSTEM & WINDOW SYSTEM)REPAIR INSTRUCTIONSHINGE REPLACEMENT - DOOR (NOT RPO PRP)REMOVAL PROCEDURE

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Removal Procedure

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, and 2002 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.

Remove the sealer that surrounds the hinge.
Scribe the location of the existing hinges on the body pillar or the door.
Mark the approximate centers of the Mig welds on the hinge base.

Fig 1: Removing Sealer Surrounding Hinge
Courtesy of GENERAL MOTORS CORP.
Drill a 3 mm (1/8 in) pilot hole (5) completely through the spot welds (4) at each center punch mark.
Drill a 13 mm (1/2 in) hole through the hinge base (6) and the body pillar or the door using the smaller hole as a pilot.

Fig 2: Drilling Hole Through Hinge Base
Courtesy of GENERAL MOTORS CORP.
A small amount of weld may still retain the hinge base to the body pillar or the door. Drive a chisel between the hinge base and the body pillar or the door in order to separate the hinge from the body pillar or the door.

Fig 3: Separating Hinge From Body Pillar Or Door
Courtesy of GENERAL MOTORS CORP.
Remove the hinges from the door or the body pillar.

Fig 4: Removing Hinges From Door Or Body Pillar

Courtesy of GENERAL MOTORS CORP.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.