Here's a general outline. Specific steps might vary slightly depending on your exact trim level and any aftermarket modifications. Always refer to a repair manual specific to your year and model for detailed diagrams and torque specifications.
1. Preparation:
* Gather Tools: You'll need various sockets, wrenches (including a 15mm socket for the hinge bolts most likely), screwdrivers (Phillips and possibly flathead), a helper, jack stands (highly recommended), and possibly a door support (to prevent the door from dropping). A torque wrench is essential for proper reassembly.
* Disconnect Interior Components:
* Window Regulator: Disconnect the electrical connector for the window motor.
* Door Lock: Disconnect the electrical connector for the door lock mechanism.
* Interior Door Handle: Remove the interior door panel. This usually involves removing screws around the edges and possibly a few hidden behind trim pieces. Consult a repair manual for the exact procedure.
* Door Lock Actuator Rod: Disconnect the rod connecting the interior handle to the lock mechanism.
* Power Mirror Switch (if applicable): Disconnect the electrical connector.
* Speaker: Remove the door speaker to gain better access.
2. Removing the Door:
* Upper Hinge Bolts: Support the door to prevent it from dropping. Carefully remove the two bolts securing the top hinge to the door and the vehicle body. These are typically 15mm bolts but could vary.
* Lower Hinge Bolts: Repeat the process for the two bolts securing the lower hinge to the door and vehicle body. Again, these are likely 15mm, but confirm with your repair manual.
* Lower the Door: Carefully lower the door. Have your helper support the door's weight to prevent damage or injury. The door is heavy!
* Disconnect Wiring Harness: Once the hinges are unbolted, there will be a wiring harness connected to the door. Carefully unplug this harness.
3. Replacing Bushings and Pins:
* Inspect Hinges: Examine the hinges carefully to assess the condition of the bushings and pins.
* Remove Old Bushings and Pins: This may require specialized tools depending on the type of bushings. Some may be pressed in and require a press to remove. Others might be easily removed with a punch and hammer. Be careful not to damage the hinge itself.
* Install New Bushings and Pins: Carefully install the new bushings and pins. Again, a press may be necessary.
* Clean and Lubricate: Clean any debris from the hinges and lubricate them with a suitable lubricant.
4. Reinstalling the Door:
* Connect Wiring Harness: Reconnect the wiring harness to the door.
* Align the Door: Carefully align the door with the hinges and install the lower hinge bolts first, then the upper hinge bolts. This step requires precision to ensure the door aligns correctly with the door jamb.
* Tighten Bolts: Tighten the bolts to the manufacturer's specified torque using a torque wrench. Don't overtighten!
* Reconnect Interior Components: Reconnect all the interior components (door panel, speaker, window regulator, etc.) that you removed earlier.
* Test the Door: Check the door operation and make sure the door opens and closes smoothly.
Important Considerations:
* Repair Manual: A factory service manual is invaluable for this job. It provides detailed instructions, diagrams, and torque specifications specific to your 2002 Silverado.
* Safety: Always prioritize safety. Use jack stands to support the vehicle, have a helper assist with the heavy door, and wear safety glasses.
* Patience: This is not a quick job. Take your time and be methodical to avoid damaging anything.
If you're not comfortable performing this repair yourself, it's best to take your Silverado to a qualified mechanic. Improperly installed hinges can lead to door alignment issues and safety hazards.
