Trunk / Liftgate Hinge: Service and Repair

Cargo Body Side Hinge Replacement

Upper Cargo Hinge

REMOVAL PROCEDURE

1. Visually inspect and restore as much of the damage as possible to factory specifications.
2. Remove all of the related panels and the components.




3. Remove any excess sealer surrounding the hinge (Fig. 4-44).




4. Scribe the location of the hinge on the hinge pillar (Fig. 4-45).




5. Locate and drill out all necessary factory welds in the hinge access panel. (Fig. 4-46).




6. Pry access door out to gain access to the back side of the hinge (Fig. 4-47).




7. Locate and drill the center of the hinge welds using a 13 mm (1/2 in) drill bit or the equivalent (Fig. 4-48).




8. If necessary, use a chisel in order to separate the hinge from the pillar (Fig. 4-49).




9. Remove the hinge (Fig. 4-50).

INSTALLATION PROCEDURE




1. Clean and prepare the pillar surface in order to ensure a flush fit of the service hinge and the fasteners (Fig. 4-51).

IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 "GM Approved Refinish Materials" for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

2. Apply approved anti-corrosion primer.




3. Apply full-bodied caulk to the entire hinge mounting surface (Fig. 4-52).




4. Position the service hinge within the scribe marks on the pillar (Fig. 4-53).

NOTE: Refer to Fastener Notice in Service Precautions.

5. Install the hinge fasteners. Tighten the bolts to 25 N.m (20 lb.Ft.).
6. Refinish the metal surfaces as necessary.
7. Align and install all of the related panels and the components.

Lower Cargo Hinge

REMOVAL PROCEDURE

1. Visually inspect and restore as much of the damage as possible to factory specifications.
2. Remove all of the related panels and the components.




3. Remove any excess sealer surrounding the hinge (Fig. 4-54).




4. Scribe the location of the hinge on the hinge pillar (Fig. 4-55).




5. 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 (Fig. 4-56).




6. Center punch each of the four weld marks on the original hinge (Fig. 4-57).




7. Locate and drill out all necessary factory welds in the rear body opening lower filler, using 8 mm (5/16 in) spot weld remover, to gain access to the backside of the lower hinge (Fig. 4-58).

IMPORTANT: Take care not to damage the filler panel when removing it. The filler panel must be reinstalled (Fig. 4-59).




8. Remove rear body opening lower filler. If necessary, use a chisel in order to separate the filler from the opening (Fig. 4-59).

IMPORTANT: Do not drill into the hinge pillar.




9. Drill through the hinge only at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or the equivalent (Fig. 4-60).




10. If necessary, use a chisel in order to separate the hinge from the pillar (Fig. 4-61).
11. Remove the hinge.




12. Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge (Fig. 4-62).

INSTALLATION PROCEDURE

1. Repair any damage done to the pillar during the drilling or the removal.
2. Position the service hinge within the scribe marks on the pillar.




3. Center punch each bolt location on the pillar according to the service hinge (Fig. 4-63).




4. Drill a 3 mm (1/8 in) pilot hole at each punch location (Fig. 4-64).




5. Drill a 13 mm (1/2 in) hole at the pilot locations (Fig. 4-65).
6. Clean and prepare all bare metal surfaces.

IMPORTANT: Prior to refinishing, refer to the publication GM4901M-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. Apply full-bodied caulk to the entire hinge mounting surface (Fig. 4-66).




9. Align hinge with the holes in the pillar (Fig. 4-67).




10. Install the hinge fasteners (Fig. 4-68).
11. Tighten the bolts to 25 N.m (20 lb.Ft.).




12. Position the rear body opening lower filler and mig-weld in place at factory weld locations (Fig. 4-69).
13. Clean and prepare all weld surfaces.
14. Refinish the metal surfaces as necessary.
15. Align and install all of the related panels and the components.