Doors - Front Door Hinge Pin and Bushing Wear
File In Section: 10 - BodyBulletin No.: 26-16-03
Date: October, 1994
Subject:
Front Door Hinge Pin/Bushing Wear
(Service Procedure)
Models:
1988-93 Chevrolet and GMC Truck C/K Models
1990-93 Chevrolet and GMC Truck Topkick/Kodiak Models
This bulletin is being revised to add the 1993 model year and additional correction information. Previous divisional publication numbers were:
Chevrolet 2-184-10
GMC Truck 92-10-82
GM Canada 92-2-500
Condition
Some owners may experience front door hinge pins and/or bushings wearing in extreme operating conditions as listed below. If this wear is not addressed early enough, minor cracks may appear in the sheet metal. If the cracks are not addressed early enough, the door hinge may separate from the sheet metal.
Cause
The cause is excessive force on the bushing at the door stop. Worn or damaged hinge pins and/or bushings may cause the door to sag, which can prevent the door from closing properly. If the hinge pin bushings are worn and this condition is not corrected, the hinge pin may wear through the bushing and into the parent metal of the hinge.
Hinge pin and bushing wear or damage is commonly found on vehicles which operate in the following environments:
1. Operations where there is a very high number of door open/closings per day (over 100 times/day).
2. An extremely dusty or dirty environment.
Correction
Three situations have been identified with the appropriate correction listed.
Situation 1 - The hinge bushings, hinge pins and/or door stop check pin are worn out or damaged.
1. If necessary, replace the door stop check pin.
2. If necessary, replace hinge bushings and hinge pins.
3. Add door trim strap assembly.
4. Lube door hinge and lube again at each oil change as ongoing preventative maintenance.
Situation 2 - The door hinges are damaged in the bushing area and new service replacement hinges and plates are needed.
1. Refer to the Service Manual for instruction on replacing hinges.
2. Add door trim strap assembly.
3. Lube door hinge and lube again at each oil change as ongoing preventative maintenance.
Situation 3 - Minor cracks in the sheet metal around the door hinge area, and bushings are worn out or damaged (no damage to hinges).
1. Install plates to reinforce existing hinges.
2. If necessary, replace the door stop check pin.
3. If necessary, replace hinge bushings and hinge pins.
4. Add door trim strap assembly.
5. Lube door hinge and lube again at each oil change as ongoing preventative maintenance.
History
There were production changes which were made to address this situation, and they are listed here with the approximate time the change went into effect at the assembly plants.
1. Lubrication released for hinge bushings, March 1991.
2. Molybdenum disulfide coating added to hinge pin for improved lubrication, February 1992.
3. Cab door frame reinforcement redesigned from 1.5 mm to 2.0 mm thick and darts added, February 1992.
4. Retaining groove added to hinge pin, March 1992.
5. Tapered check pin replaced non-tapered check pin, October 1992.
6. Non-serrated bronze bushings replace stainless bushings, November 1992.
7. Door hinge "Z" reinforcement added April 1993.
Service Procedures
The service procedures may vary for each truck, depending on the severity of the damage. The technician should evaluate each case to determine the extent of the modifications required.
A. Replace Hinge Pin and/or Hinge Bushing
B. Replace Door Stop Check Pin
C. Install Plates to Reinforce Existing Hinges
D. Install Door Trim Strap Kit
E. Replace Door Hinge
A. Service Procedure to Replace Hinge Pin and/or Hinge Bushing
1. Refer to the Service Manual, Section 10A1 Door Replacement for procedures on how to remove the door and replace hinge pins.
2. Dealers should refer to Medium Duty Service Manual, Section 10A1-2 for Hinge Bushing Replacement procedures.
Parts Information to Replace Hinge Pin and/or Bushing
Parts are currently available from GMSPO.
B. Service Procedure to Replace Door Stop Check Pin
1. Dealers should refer to Medium Duty Service Manual, Section 10A1-3 for Door Stop Check Pin Replacement procedures.
Parts Information to Replace Door Stop Check Pin
Qty
P/N Description Door
12540326 Door Stop Check Pin 1
Parts are currently available from GMSPO.
C. Service Procedure to Install Plates, Reinforcing Existing Hinges
1. Refer to Service Manual, Section 10A1 Doors for Hinge Replacement procedures. Use existing hinges if they are not damaged in place of new hinges.
2. Experienced technicians have advised that they have found it easier to use a spot weld drill to oversize the four holes and then tack-weld the four bolts to the back plate before installing it into the cowl. This prevents the technician from having to hold the plates during hinge adjustment. A couple of peens to the pins also helps secure them better in the hinge, and a spot of Loctite(R).
Parts Information to Install Plates, Reinforcing Existing Hinges
Parts are currently available from GMSPO.
D. Service Procedure to Install Door Trim Strap Kit
1. Roll the window down all the way and remove the cowl kick trim panel.
2. Remove the window crank handle, the door handle trim plate, and the 2 armrest screws to remove the door trim panel. Refer to bulletin 361015 dated February 1994 on Door Trim Panel Removal.
3. Partially peel back the tar paper from the area nearest the door hinge. Refer to Figure 1, View A.
4. Roll up the window all the way. Remove lower bolt and washer from the door window run channel and discard.
5. Bolt the lower part of the door trim strap bracket to the door at the vacant hole (upper window run channel bolt hole). Refer to Figure 2 for correct placement of bracket to the vehicle. Mark drilling location for upper part of the door trim strap bracket with a punch. Hit the punch with the tip through the hole in the check bracket. Use a 9 mm drill bit and drill a hole through the hole in the check bracket.
6. Attach the top part of the door trim strap bracket with a bolt, a washer and a nut. The washer should go on sides of the sheet metal (bolt-washer-bracket-sheet metal-nut assembly).
7. Install screw assembly in the bottom hole of the door trim strap bracket.
8. To attach the door trim strap assembly in the cowl kick trim panel area, remove the sill plate and cowl kick panel.
9. Use template # 1 to mark two drill and one self tapping screw locations with center punch tool.
10. Drill two 9 mm holes in the two locations closest to the door hinge. Do not drill third location.
11. Bolt the door trim strap anchor bracket to the kick panel area using two bolts, two washers and two nuts (bolt-washer-bracket-sheet metal-nut assembly).
12. Install the self tapping screw to the third hole of the anchor bracket. The door trim strap kit should be installed at this point.
13. To modify cowl kick panel to prevent interference with the door trim strap kit, use template # 2 to mark notch area on cowl kick panel. Out plastic cowl kick panel with an air saw, hack saw, or pocket knife.
14. Cut off two of the four retainer blades as shown in Figure 3. One of the cut off blades has a retainer clip. Remove the retainer clip from the cut off blade and install the clip on the remaining blade of the cowl kick trim panel. In summary,
a. Remove clip from one of the blades.
b. Cut 2 of the 4 plastic blades.
c. Reinstall clip on remaining blade.
15. Install the cowl kick trim panel.
16. To modify the door trim panel to prevent interference with the door trim strap kit, use template # 3 to mark notch area on door trim panel. Cut notch in the plastic door trim panel with an air saw, hack saw, or pocket knife.
17. Install the door trim panel.
18. Figure 4 illustrates the installed door trim Strap kit.
Parts Information to Install Door Trim Strap Kit
Parts are currently available from GMSPO.
E. Service Procedure to Replace Door Hinge
1. Refer to the Service Manual, Section 10A1 Doors for procedures on replacing the door hinges.
Parts Information to Replace Door Hinge
Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty, use published labor operation numbers and labor times from the Labor Time Guide for performing the following corrections.
A. Replace Hinge Pin and/or Hinge Bushing
B. Replace Door Stop Check Pin
C. Install Plates to Reinforce Existing Hinges
D. Replace Door Hinge
For vehicles repaired under warranty, use the labor operation number and labor time for installing the door trim strap kit assembly.