GM Astro/Safari 1985-1996 Repair Guide

Front Door Hinges

Print

The following procedure requires the use of an1/8in. (3mm) drill bit,1/2in. (13mm) drill bit, a center punch, a cold chisel, a portable body grinder, a putty knife, and a scribing tool.

REMOVAL & INSTALLATION



See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Installing replacement door hinges onto the vehicle



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the front door alignment points

  1. Refer to the Door, Removal and Installation procedures in this section and remove the door(s), then place the door on a padded workbench.
  2.  
  3. Using a putty knife, remove the sealant from the around the edge of the hinge.
  4.  
  5. Using a scribing tool, outline the position of the hinge(s) on the door and the body pillar.
  6.  
  7. Using a center punch, mark the center position of the hinge-to-door and the hinge-to-body pillar welds.
  8.  
  9. Using a 1 / 8 in. (3mm) bit, drill a pilot hole completely through each weld.
  10.  

When drilling the holes through the hinge welds, DO NOT drill through the door or the body pillar.

  1. Using a 1 / 2 in. (13mm) bit, drill a hole through the hinge base, following the 1 / 8 in. (3mm) pilot hole.
  2.  
  3. Using a cold chisel and a hammer, separate the hinge from the door and/or the body pillar. Using a portable grinder, clean off any welds remaining on the door or the body pillar.
  4.  

To install:
  1. To fasten the replacement hinge(s) to the door and/or body pillar, perform the following procedures:
    1. Align the replacement hinge, with the scribe lines, previously made.
    2.  
    3. Using a center punch and the new hinge as a template, mark the location of each bolt hole.
    4.  
    5. Using a 1 / 2 in. (13mm) bit, drill holes (using the center marks) through the door and body pillar.
    6.  
    7. If the upper body side hinge is to be replaced, remove the instrument panel fasteners, pull the panel outwards and support it.
    8.  

  2.  
  3. Use medium body sealant (apply it to the hinge-to-door or body pillar surface), the hinge-to-door/body pillar bolts and tapped anchor plate.
  4.  
  5. Tighten the hinge-to-door/body pillar bolts to 20 ft. lbs. (27 Nm).
  6.  
  7. Apply paint to the hinge and the surrounding area.
  8.  

ADJUSTMENT



See Figures 3, 4 and 5



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the front door striker mounting



Click image to see an enlarged view

Fig. Fig. 4: If the striker must be removed, first scribe an alignment mark ...



Click image to see an enlarged view

Fig. Fig. 5: ... then loosen the striker using a suitable driver (usually a Torx®)

The1/2in. (13mm) drill hinge holes provide for some adjustment.

  1. Loosen, adjust, then tighten the hinge-to-door/body pillar bolts; close the door, then check the door gap, it should be 4-6mm between the door and the door frame.
  2.  
  3. With the door closed, it should be flush, plus or minus 1.0mm, with the body; if not, enlarge the striker hole.
  4.  

 
label.common.footer.alt.autozoneLogo