2005 GMC Savana cargo door hinge broken

if the welded half is broken, I'd use a die-grinder and cut the weld to remove the broken part. You can grind on the old weld and broken part, just don't grind on what your trying to save. Hopefully you can remove hinge pin to remove door. Weld on new hinge.

I didn't mention using a cutting torch to remove the hinge, wasn't sure what the heat might do? Whichever way you get the hinge off, watch out where the sparks are flying.

If you don't have access to welder, you might take it to a body shop.

I've never had to remove one of these hinges. Those hinges are a little pricey.

I wonder if other is a factory procedure for lining up the hinge on the door post or visit trial and error.

I was thinking about that, I'd use a marker all around that broken hinge, before you take it off. Then when you tack on the new hinge, try the door on it before you nail the hinge down. I don't know an easier way? You will probably need some helpers, that door may be heavy?