2002 Avalanche 3-5
Front Lower Hinge
Pillar Sectioning
Removal Procedure
1. Visually inspect and restore as much of
the damage as possible to factory
specifications.
2. Remove all related panels and
components.
3. Note the location and remove the
following as necessary:
• Sealers
• Sound deadeners
• Anti-corrosion materials
4. Measure 80␣ mm (3-1/8 inches) down
from the large wiring harness hole in the
hinge pillar and mark a horizontal line.
5. Cut the pillar in the locations where
sectioning is to be performed.
IMPORTANT: Take care not to damage
the inner panel.
6. Locate, mark and drill out all necessary
factory welds. Note the number of welds
for the installation of the service section.
7. Remove the damaged section of the door
frame opening.
IMPORTANT: The metal of the hinge
pillar is of a heavy gauge. However, the
tabs can be created using the appropriate
tools.
8. Cut and remove 30␣ mm (1-3/16 inches)
from the flanges on either side of the
remaining section of the original hinge
pillar to create 30␣ mm (1-3/16␣ in.) tabs.
Cut 5␣ mm (3/16␣ in.) wide gaps in the
bottom corners.
9. Step the tabs inward to allow the door
frame opening service section to fit over
the original hinge pillar. Weld the tabs
together along the edges.
80 MM (3-1/8 IN)
ORIGINAL
PANEL
30 MM (1-3/16 IN)
5 MM (3/16 IN)
WELD TOGETHER
