2002 Avalanche 3-1
1
Door Frame
Sectioning
IMPORTANT: Section in specified areas
only. Sectioning outside of these areas
may compromise the structural integrity
of the vehicle. Do not section in laser
weld (1) areas of door frame sections.
The door frame opening is a unique
laser-weld design incorporating multiple
metal thicknesses to ensure the
structural integrity of the cab. The door
frame can be replaced at factory seams,
but requires the removal of the roof
panel, windshield and quarter panel.
Sectioning procedures have been
developed as a more cost-effective
alternative to complete replacement. The
specific area to be sectioned is
determined by the extent of the damage
to the vehicle.
2002 Chevrolet Avalanche
2002 Chevrolet Avalanche
3-2 2002 Avalanche
Windshield Pillar
Sectioning
Removal Procedure
1. Remove all related panels and
components.
2. Restore as much of the damage as
possible to factory specifications.
3. Note the location and remove the
following as necessary:
• Sealers
• Sound deadeners
• Anti-corrosion materials
IMPORTANT: Perform sectioning
in the windshield area 30␣ mm
(1-3/16␣ in.) above the third trim
mounting hole.
IMPORTANT: Take care not to
damage the inner panels or
reinforcements.
4. Cut the pillar in the locations where
sectioning is to be performed.
5. Locate and drill out all factory
welds. Note the number and
location of the welds for installation
of the service part.
6. Remove the damaged Windshield
Pillar section.
30 MM (1-3/16 IN)
50 MM (2 IN)
2002 Avalanche 3-3
Windshield Pillar
Sectioning
Installation Procedure
1. Cut the replacement pillar in
corresponding locations to fit the
remaining original panel. The
sectioning joint should be trimmed
to allow a gap of one and one-half
times the metal thickness at the
sectioning joint.
2. Create a 50␣ mm (2␣ in.) backing
plate from the unused portion of the
service part. Trim the backing plate
as necessary to fit behind the
sectioning joint.
3. Perform additional sectioning
procedures as necessary. Refer to
Center Pillar Sectioning; Front
Lower Pillar Sectioning; Rear Lock
Pillar Sectioning; and Rocker
Sectioning.
4. Drill 8␣ mm (5/16␣ in.) holes for plug
welding in the original part. Locate
these holes approximately 13␣ mm
(1/2␣ in.) from the edge of the
sectioning cuts and spaced 40␣ mm
(1-1/2␣ in.) apart.
5. Drill 8␣ mm (5/16␣ in.) plug weld
holes in the service panel as
necessary in the locations noted
from the original panel and along
the sectioning cut.
CAUTION: FOAM SEALERS ARE
FLAMMABLE AND SHOULD BE
REMOVED FROM ALL WELD
LOCATIONS.
6. Prepare the mating surfaces, as
necessary.
7. Apply weld-through primer to all
bare metal surfaces.
8. Fit the backing plate halfway into
the sectioning joint, clamp and plug
weld to the vehicle.
9. Align the Windshield Pillar to
adjacent panels using three-
dimensional measuring equipment.
10. Plug weld accordingly.
—continued
PLUG WELDS
13 MM
(1/2 IN)
ORIGINAL PART
BACKING PLATE
50 MM
(2 IN)
100 MM
(4 IN)
100MM
(4 IN)
BACKING PLATE
GAP = ONE AND ONE-HALF TIMES
THE THICKNESS OF THE METAL
3-4 2002 Avalanche
GAP =
ONE AND ONE-HALF TIMES
METAL THICKNESS
STITCH WELD
Windshield Pillar Sectioning
Installation Procedure con’t
11. Make 25␣ mm (1␣ in.) stitch welds
along the seam with 25␣ mm (1␣ in.)
gaps between them, then go back
and complete the stitch weld. This
will create a solid joint with minimal
heat distortion.
12. Clean and prepare all welded
surfaces.
IMPORTANT: Prior to refinishing,
refer to the publication GM4901M-
D-01 GM Approved Refinish
Materials for recommended
products. Do not combine paint
systems. Refer to paint
manufacturer’s recommendations.
13. Apply an approved anti-corrosion
primer.
14. Apply sealers and refinish as
necessary.
15. Install all related panels and
components.
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
3-6 2002 Avalanche
Front Lower Hinge
Pillar Sectioning
Installation Procedure
1. On the service part, measure 50␣ mm (2␣ in.)
down from the large wiring harness hole in
the hinge pillar and mark a horizontal line.
Cut the hinge pillar along this line.
2. Perform additional sectioning procedures as
necessary to remove the unused areas of
the service part. Refer to Windshield
Sectioning; Center Pillar, Rear Lock Pillar,
and Rocker Sectioning.
NOTICE: In any area damaged beyond
recognition, space plug weld holes every
40␣ mm (1-1/2␣ in.) apart.
3. Drill 8␣ mm (5/16␣ in.) plug weld holes as
necessary in the locations noted from the
original section. Also drill plug weld holes
along the hinge pillar sectioning cut of the
service part. These should be located
approximately 15␣ mm (9/16␣ in.) from the
edge of the cut.
CAUTION: FOAM SEALERS ARE
FLAMMABLE AND SHOULD BE
REMOVED FROM ALL WELD
LOCATIONS.
4. Prepare mating surfaces as necessary.
5. Apply weld-thru primer to all bare-metal
surfaces.
6. Position the service section over the
stepped tab on the original hinge pillar,
allowing 30␣ mm (1-3/16 inches) of overlap.
Check fit using three-dimensional
measuring.
7. Plug weld service part in position.
8. Make 25␣ mm (1␣ in.) welds along the seam
with 25␣ mm (1␣ in.) gaps between. Then go
back and complete the stitch weld. This
will create a solid joint with minimal heat
distortion.
9. Clean and prepare all welded surfaces.
IMPORTANT: Prior to refinishing,
refer to the publication GM4901M-D-01
GM Approved Refinish Materials for
recommended products. Do not combine
paint systems. Refer to paint manufacturer’s
recommendations.
10. Apply an approved anti-corrosion primer.
11. Apply sealers and refinish as necessary.
12. Install all related panels and components.
50 MM (2 IN)
SERVICE
PANEL
ORIGINAL
PANEL
NEW
SERVICE PANEL
ORIGINAL
PANEL
30 MM (1-3/16 IN)
OF OVERLAP
2002 Avalanche 3-7
Center Pillar
Sectioning
Removal Procedure
1. Remove all related panels and
components.
2. Restore as much of the damage as
possible to factory specifications.
3. Note the location and remove the
following as necessary:
• Sealers
• Sound deadeners
• Anti-corrosion materials
IMPORTANT: Take care not to
damage the inner panels or
reinforcements.
4. Cut the Center Pillar in the location
where sectioning is to be performed.
5. Locate and drill out all factory
welds. Note the number and
location of the welds for installation
of the service part.
6. Remove the damaged Center Pillar
section.
1
3-8 2002 Avalanche
Center Pillar
Sectioning
Installation Procedure
1. Cut the replacement Center Pillar in
corresponding locations to fit the
remaining original panel. The sectioning
joint should be trimmed to allow a gap of
one-and-one-half times the metal
thickness at the sectioning joint.
2. Create a 50␣ mm (2␣ in.) backing plate
from the unused portion of the service
part. Trim the backing plate as necessary
to fit behind the sectioning joint.
3. Perform additional sectioning procedures
as necessary. Refer to Windshield
Sectioning; Front Lower Pillar
Sectioning; Rear Lock Pillar Sectioning;
and Rocker Sectioning.
4. Drill 8␣ mm (5/16␣ in.) plug weld holes
along the sectioning cut on the
remaining original part.
5. Drill 8␣ mm (5/16␣ in.) plug weld holes in
the service panel as necessary in the
locations noted from the original panel
and along the sectioning cut.
CAUTION: FOAM SEALERS ARE
FLA␣ MMABLE AND SHOULD BE
REMOVED FROM ALL WELD
LOCATIONS.
6. Prepare the mating surfaces as necessary.
7. Apply weld-through primer to all bare
metal surfaces.
8. Fit the backing plate halfway into the
sectioning joint, clamp and plug weld to
the vehicle.
—continued
1
50MM
(2 IN)
100MM
(4 IN)
PLUG WELDS
13 MM
(1/2 IN)
ORIGINAL PART
BACKING PLATE
2002 Avalanche 3-9
GAP =
ONE AND ONE-HALF TIMES
METAL THICKNESS
STITCH WELD
Center Pillar Sectioning
Installation Procedure con’t
9. Align the Center Pillar to adjacent
panels using three-dimensional
measuring equipment.
10. Plug weld accordingly.
11. Make 25␣ mm (1␣ in.) stitch welds
along the seam with 25␣ mm (1␣ in.)
gaps between them, then go back
and complete the stitch weld. This
will create a solid joint with minimal
heat distortion.
12. Clean and prepare all welded
surfaces.
IMPORTANT: Prior to refinishing,
refer to the publication GM4901M-
D-01 GM Approved Refinish
Materials for recommended
products. Do not combine paint
systems. Refer to paint
manufacturer’s recommendations.
13. Apply an approved anti-corrosion
primer.
14. Apply sealers and refinish as
necessary.
15. Install all related panels and
components.
3-10 2002 Avalanche
Rear Lock Pillar
Sectioning
Removal Procedure
1. Remove all related panels and components.
2. Restore as much of the damage as possible to
factory specifications.
3. Note the location and remove the following
as necessary:
• Sealers
• Sound deadeners
• Anti-corrosion materials
IMPORTANT: Take care not to damage the
inner panels or reinforcements.
4. Cut the Rear Lock Pillar in the locations
where sectioning is to be performed.
5. Locate and drill out all factory welds. Note
the number and location of the welds for
installation of the service part.
6. Remove the damaged Rear Lock Pillar
section.
1
2002 Avalanche 3-11
Rear Lock Pillar
Sectioning
Installation Procedure
1. Cut the replacement Rear Lock
Pillar in corresponding locations to
fit the remaining original panel. The
sectioning joint should be trimmed
to allow a gap of one-and-one-half
times the metal thickness at the
sectioning joint.
2. Create a 50␣ mm (2␣ in.) backing
plate from the unused portion of the
service part. Trim the backing plate
as necessary to fit behind the
sectioning joint.
3. Perform additional sectioning
procedures as necessary. Refer to
Windshield Sectioning; Front Lower
Pillar Sectioning; Center Pillar; and
Rocker Sectioning.
4. Drill 8 ␣ mm (5/16␣ in.) plug weld
holes along the sectioning cut on
the remaining original part.
5. Drill 8␣ mm (5/16␣ in.) plug weld
holes in the service panel as
necessary in the locations noted
from the original panel and along
the sectioning cut.
CAUTION: FOAM SEALERS ARE
FLAMMABLE AND SHOULD BE
REMOVED FROM ALL WELD
LOCATIONS.
6. Prepare the mating surfaces, as
necessary.
7. Apply weld-through primer to all
bare metal surfaces.
8. Fit the backing plate halfway into
the sectioning joint, clamp and plug
weld to the vehicle.
BACKING PLATE
50 MM
(2 IN)
100 MM
(4 IN)
PLUG WELDS
13 MM
(1/2 IN)
ORIGINAL PANEL
BACKING PLATE
3-12 2002 Avalanche
GAP =
ONE AND ONE-HALF TIMES
THE METAL THICKNESS
STITCH WELD
Rear Lock Pillar Sectioning
Installation Procedure con’t
9. Align the Rear Lock Pillar to
adjacent panels using three-
dimensional measuring equipment.
10. Plug weld accordingly.
11. Make 25␣ mm (1␣ in.) stitch welds
along the seam with 25␣ mm (1␣ in.)
gaps between them, then go back
and complete the stitch weld. This
will create a solid joint with minimal
heat distortion.
12. Clean and prepare all welded
surfaces.
IMPORTANT: Prior to refinishing,
refer to the publication GM4901M-
D-01 GM Approved Refinish
Materials for recommended
products. Do not combine paint
systems. Refer to paint
manufacturer’s recommendations.
13. Apply an approved anti-corrosion
primer.
14. Apply sealers and refinish as
necessary.
15. Install all related panels and
components.
2002 Avalanche 3-13
Rocker Panel
Sectioning
Removal Procedure
1. Remove all related panels and
components.
2. Restore as much of the damage as
possible to factory specifications.
3. Note the location and remove the
following as necessary:
• Sealers
• Sound deadeners
• Anti-corrosion materials
IMPORTANT: Take care not to
damage the inner panels or
reinforcements.
4. Cut the Rocker Panel in the
locations where sectioning is to be
performed.
5. Locate and drill out all factory
welds. Note the number and
location of the welds for installation
of the service part.
6. Remove the damaged Rocker Panel
section.
1
3-14 2002 Avalanche
Rocker Panel
Sectioning
Installation Procedure
1. Cut the replacement Rocker Panel in
corresponding locations to fit the
remaining original panel. The sectioning
joint should be trimmed to allow a gap of
one-and-one-half times the metal thickness
at the sectioning joint.
2. Create a 100␣ mm (4␣ in.) backing plate
from the unused portion of the service
part. Trim the backing plate as necessary
to fit behind the sectioning joint.
3. Perform additional sectioning procedures
as necessary. Refer to Windshield
Sectioning; Front Lower Pillar Sectioning;
Rear Lock Pillar Sectioning; and Center
Pillar sectioning.
4. Drill 8␣ mm (5/16␣ in.) plug weld holes along
the sectioning cut on the remaining
original part.
5. Drill 8␣ mm (5/16␣ in.) plug weld holes in
the service panel as necessary in the
locations noted from the original panel and
along the sectioning cut.
CAUTION: FOAM SEALERS ARE
FLAMMABLE AND SHOULD BE
REMOVED FROM ALL WELD
LOCATIONS.
6. Prepare the mating surfaces as necessary.
7. Apply weld-through primer to all bare
metal surfaces.
8. Fit the backing plate halfway into the
sectioning joint, clamp and plug weld to
the vehicle.
9. Align the Rocker Panel to adjacent panels
using three-dimensional measuring
equipment.
10. Plug weld service part in position.
11. Make 25␣ mm (1␣ in.) stitch welds along the
seam with 25␣ mm (1␣ in.) gaps between
them, then go back and complete the
stitch weld. This will create a solid joint
with minimal heat distortion.
12. Clean and prepare all welded 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.
13. Apply an approved anti-corrosion primer.
14. Apply sealers and refinish as necessary.
15. Install all related panels and components.
100 MM
(4 IN)
BACKING PLATE
GAP = ONE AND ONE-HALF TIMES
THE THICKNESS OF THE METAL
2002 Avalanche 3-15
HINGE
PILLAR
13 MM (1/2 IN)
ROTABROACH BIT
HINGE REINFORCEMENT
TYPICAL MIG WELD
DRILL THROUGH HINGE ONLY
Front Body-Side
Hinge Replacement
Removal Procedure
1. Remove related panels and
component.
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.
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.
IMPORTANT: Do not drill into the
hinge pillar.
5. Drill through the hinge 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.
3-16 2002 Avalanche
Front Body-Side
Hinge Replacement
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 stud location on
the hinge pillar according to the
service hinge.
4. Drill a 3 ␣ mm (1/8␣ in.) pilot hole at
each center punch location.
IMPORTANT: Drill must be exact size.
5. Drill an 11.5 mm (29/64␣ in.) hole at
the pilot locations for the studs.
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.
6. Clean and prepare all of the bare
metal surfaces.
7. Apply an approved anti-corrosion
primer.
8. Feed fish wire, 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 the stud, 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 tight through the
pillar. Use the nuts (GM P/N
11516746) supplied.
12. Repeat steps 7-10 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.
3 MM (1/8 IN)
PILOT
11.5 MM (29/64 IN)
DRILL
2002 Avalanche 3-17
Hinge
Nuts
Pillar
Hinge
Reinforcement
Studs
Front Body-Side Hinge
Replacement
Installation Procedure con’t
15. Install the hinge to the pillar. Use
the supplied nuts.
16. Torque the hinge to the pillar nuts
to 25␣ ␣ N·m (18 ft lb.).
17. Clean and prepare all of the
surfaces as necessary for refinishing.
18. Apply the sealers. Refinish the
surfaces as necessary.
19. Install and align all of the related
panels and the components.
3-18 2002 Avalanche
Front Door-Side
Hinge Replacement
Removal Procedure
1. Remove related panels and
components.
2. Remove any excess sealer surrounding
the hinge and scribe the location of
the hinge on the door.
3. Lightly hand-sand the existing body
hinge with 100 grit or finer sandpaper
in order to locate the 4 welds that
attach the hinge to the door.
IMPORTANT: Punch the center of the
weld so that as much of the weld is
removed during the drilling as possible.
4. Center punch each of the four weld
marks on the original hinge base.
IMPORTANT: Do not drill into the
door.
5. Drill through hinge base only at the
punch location. Use a 13 mm (1/2␣ in.)
rotabroach hole saw, or the equivalent.
6. Remove hinge. If necessary, use a
chisel to separate the hinge from the
door.
7. Remove all of the remaining weld from
the door surface in order to ensure a
flush fit of the service hinge.
13mm (1/2 inch)
Rotabroach Bit
Hinge
Door
Hinge Reinforcement
Typical Mig Weld
Drill through hinge only
2002 Avalanche 3-19
Front Door-Side
Hinge Replacement
Installation Procedure
1. Repair any damage done to door
during the drilling or the removal.
2. Clean and prepare the backing plate
mounting surfaces in order to
ensure a flush fit of the backing
plate.
3. Position the service hinge within the
scribe marks on the door.
4. Center punch each hole location on
the door according to the service
hinge.
5. Drill a 3 mm (1/8␣ in.) pilot hole at
each center punch location.
6. Drill a 13 mm (1/2␣ in.) hole at the
pilot locations.
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. Clean and prepare all of the bare
metal surfaces.
8. Apply an approved anti-corrosion
primer.
9. Apply full-bodied caulk to the entire
hinge mounting surface in order to
ensure a proper seal.
10. Align the hinge and the backing
plate with the holes in the door
(Fig. 4-34).
11. Install the bolts. Tighten the bolts
to 25 ␣ N·m (18 ft lb).
12. Apply the sealers.
13. Refinish the metal surfaces as
necessary.
14. Install and align all of the related
panels and the components.
3 MM (1/8 IN)
PILOT
13 MM (1/2 IN)
DRILL
HINGE
DOOR
BOLTS
BACKING
PLATE
3-20 2002 Avalanche
Rear Body-Side
Hinge Replacement
Removal Procedure
1. Remove 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.
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 4 weld
marks on the original hinge.
IMPORTANT: Do not drill into the
hinge pillar.
5. Drill through the hinge only at each
punch location. Use a 13␣ mm
(1/2␣ in.) rotabroach hole saw or the
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.
HINGE
PILLAR
13 MM (1/2 IN)
ROTABROACH BIT
HINGE REINFORCEMENT
TYPICAL MIG WELD
DRILL THROUGH HINGE ONLY
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