Body - Front Door Sags/Chucking Movement: Overview

File In Section: 08 - Body and Accessories

Bulletin No.: 02-08-64-016

Date: July, 2002

TECHNICAL

Subject:
Front Door Hinge Pin/Bushing Wear, Front Door Sags, or Door Chucking Movement (Service Procedures, Teflon Bushings/Severe Usage Service Kit Released)

Models:
1988-1998 Chevrolet and GMC C/K 1500/2500 Series (Classic) Pickup Models
1988-2000 Chevrolet and GMC C/K 3500 Series (Classic) Pickup Models
1990-2002 Chevrolet and GMC H Model C-Series Conventional Medium Duty Models (Topkick, Kodiak)

This bulletin is being revised to add model and parts information and additional Service Procedure information. Please discard Corporate Bulletin Number 26-16-03 (Section 10 - Body).

Condition

Some customers may comment on front door hinge pin bushing wear, front door sag, or door chucking movement in extreme operating conditions. Hinge pin and bushing wear or damage is commonly found on vehicles that operate where there is a very high number of door opening or closing cycles per day (over 100 times) or in an extremely dusty or dirty environment. If this wear is not addressed early, the door hinge may separate from the sheet metal.

Cause

The condition may be caused from excessive force on the bushing at the door stop. Worn or damaged hinge pins or bushings may cause the door to sag. This may 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 metal of the hinge.
Correction

Three situations have been identified with the appropriate correction listed below.

Situation 1 - The hinge bushings, the hinge pins, or the door stop check pin are worn or damaged.

1. If necessary, replace the door stop check pin.

2. If necessary, replace the hinge bushings and the stop pins.

3. Add a door trim strap assembly.

4. Install a severe service kit, P/N 15025840 with new Teflon(R) bushings and anti-chucking spacer.

5. Lubricate the door hinge. Lubricate the door hinge at each oil change as part of ongoing preventative maintenance.

Situation 2 - The door hinges are damaged in the bushing area and new replacement hinges are needed.

1. Refer to the appropriate Service Manual for instructions on replacing the hinges. Use the studs and conical nuts provided in the hinge kits.

2. Install a severe service kit, P/N 15025840 with new Teflon(R) bushings and anti-chucking spacer.

3. Add a door trim strap assembly.

4. Lubricate the door hinge. Lubricate the door hinge at each oil change as part of ongoing preventative maintenance.

Situation 3 - Minor cracks in the sheet metal around the door hinge area, and the bushings are worn or damaged. New replacement hinges are needed.

1. Refer to the appropriate Service Manual for instructions on replacing the hinges.

2. Install backing plates in order to reinforce the service hinges. Use bolts and nuts to attach both plates and hinges. Order backing plates and attach hardware separately. Refer to the parts information.

3. Install a severe service kit, P/N 15025840 with new Teflon(R) bushings and anti-chucking spacer.

4. Add a door trim strap assembly.

5. Lubricate the door hinge. Lubricate the door hinge at each oil change as part of ongoing preventative maintenance.

History

There were production changes made to address these situations. The following lists the production changes and the time the change went into effect at the assembly plants.

1. Lubricant released for hinge bushings, March 1991.

2. Molybdenum disulfide coating added to the hinge pin for improved lubrication, February 1992.

3. Cab door frame reinforcement redesigned for 1.5 mm (0.06 in) to 2 mm (0.08 in) thickness and darts added, February 1992.

4. Retaining groove added to the hinge pin, March 1992.

5. Tapered check pin replaced the non-tapered check pin, October 1992.

6. Non-serrated bronze bushings replaced stainless bushings, November 1992.

7. Door hinge Z reinforcement added, April 1993.

8. Teflon(R) bushings released for service only. Also included in kit P/N 15025840, July 1996. Both teflon and bronze bushings are now available separately.

9. Reinforcement plates removed from door hinge kits, February 1999.

10. Hinge studs and conical nuts added, February 1999.