GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Avalanche - 4WD 🢒 Body 🢒 Doors 🢒 Front Side Door HingeReplacement - Body Side

Removal Procedure

    Object Number: 383394 Size: SH
  1. Remove all of the related panels and components.
  2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar.
  3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar.

    4. Important: Punch the center of the weld so that as much of the weld as possible is removed during the drilling.

  4. Center punch each of the four weld marks on the original hinge.

    5. Object Number: 671119 Size: SH

    Important: Do not drill into the hinge pillar.

  5. Drill through the hinge base only, at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or equivalent.
  6. Remove the hinge. If necessary, use a chisel in order to separate the hinge from the pillar.
  7. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge.

Installation Procedure

    Object Number: 383412 Size: SH
  1. Repair any damage done to the pillar during the drilling or the removal of the hinge.
  2. Position the service hinge within the scribe marks on the pillar.
  3. Center punch each stud location on the hinge pillar according to the service hinge.
  4. Drill a 3 mm (1/8 in)  (1) pilot hole at each center punch location.

    5. Important: Drill bit must be exact size.

  5. Drill an 11.5 mm (29/64 in) hole at the pilot locations for the studs.
  6. Clean and prepare all of the bare metal surfaces.

    7. Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

  7. Apply approved anti-corrosion primer.

    8. Object Number: 383416 Size: SH
  8. Feed fish wire (1) , GM P/N  15017229 or the equivalent, through the hinge, the hinge stud hole and out of the conduit hole in the pillar
  9. Install stud (2), GM P/N 15017230, supplied with the service hinge into the wire end. Pull the stud into position.
  10. Hold the stud in position with the hinge and remove the fish wire.
  11. Draw the stud (4) tight through the pillar. Use the nuts GM P/N 11516746 supplied.
  12. Repeat steps 8-11 on the remaining stud locations.
  13. Remove each service nut.
  14. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal.

    15. Object Number: 383424 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  15. Install the hinge (2) to the pillar (3). Use the supplied nuts  (1).

    16. Tighten
    Tighten the hinge nuts (4) to 25 N·m (18 lb ft).

  16. Clean and prepare all of the surfaces as necessary for refinishing.
  17. Apply the sealers. Refinish the surfaces as necessary.
  18. Install and align all of the related panels and the components.