Doors (Front) - Hinge Pins/Bushing Wearing
9229chevy02
Number 92-184-10
Section: 10
Date: April 1992
Corporate Bulletin No.: 261603
ASE No.: B1
Subject:
FRONT DOOR HINGE PIN/BUSHING WEAR AND/OR CHECK PIN REPLACEMENT
Model and Year:
1988-92 C/K TRUCKS
Owners of some 1988-92 C/K vehicles may experience their front door hinge pins and/or bushings wearing. The condition may be caused by a lack of lubrication between the hinge pin and the bushing. Worn 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 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 200 times/day)
2. An extremely dusty or dirty environment.
To correct this condition, it will be necessary to replace the hinge pin and hinge pin bushings. A redesigned hinge pin is available with a dry lubricant on the pin. Redesigned hinge pin bushings, which are now being constructed out of bronze, are also available. The bronze bushings have a higher lubricity than the previous bushings.
Also, some customers may comment that their door stop check pin needs replacement. Previously this pin was serviced as part of the door hinge assembly. To improve customer satisfaction, this pin is now serviced separately (P/N 12540326). Instructions for installing this pin are included in this bulletin.
To replace the hinge pins or bushings, refer to "HINGE PIN AND/OR BUSHING REPLACEMENT" in the SERVICE PROCEDURE. To replace the door stop check pin, refer to "DOOR STOP CHECK PIN REPLACEMENT" in the SERVICE PROCEDURE.
SERVICE PROCEDURE:
If the hinge pin is worn through the bushing and into the hinge, replace the worn hinge. For replacement instructions, refer to section 10A1 "HINGE REPLACEMENT" in the appropriate Service Manual.
HINGE PIN AND/OR BUSHING REPLACEMENT
1. Disconnect the negative battery cable.
If the vehicle has power door components, follow the instructions below. If the vehicle is not equipped with power components, go to step 6.
On vehicles with power door components only:
2. Remove the hinge pillar trim panel (kick panel trim).
3. Disconnect the receptacles from the wiring harness.
4. Remove the retainer from the wiring harness grommet.
5. Remove the rubber conduit from the door pillar by pushing it from the vent cover side.
On all vehicles:
Important:
Apply a cloth backed tape to the door and the body pillar to guard against nicks and scratches.
CAUTION:
Before performing the following step, cover the spring with a towel to prevent the spring from dislodging and possibly causing personal injury or damage.
6. Remove the door hinge spring using special tool J 36604 and a 1/2 inch ratcheting box wrench (Figure 1, "4" and "2"). Insert the blades of the tool between the spring coils and turn the barrel nut to compress and hold the spring during removal.
7. Remove the lower hinge pin retainer (Figure 2, "3").
CAUTION:
Have a helper ready to support the door to prevent the door from falling and resulting in personal injury or damage.
8. Remove the lower hinge pin (Figure 2, "4") using locking pliers and a soft faced hammer.
9. Install a bolt temporarily through the lower hinges to hold the door in place while removing the upper hinge pin.
10. Remove the upper hinge pin retainer(Figure 2,"3").
11. Remove the upper hinge pin (Figure 2, "2").
12. Remove the temporary bolt in the lower hinge pin hole.
13. Remove the door from the vehicle.
14. Remove the bushings from the hinge using a hammer and chisel (Note which bushing has a larger inside diameter).
15. Install the upper and lower bushings into the hinges.
Note:
The bushings with the larger inside diameter (P/N 15691494) go into the upper hinge lower and lower hinge upper.
Bushings with the smaller inside diameter go in the upper hinge upper and the lower hinge lower (P/N 15691493).
The shoulder on the upper bushing must face up.
The shoulder on the lower bushing must face down.
16. Install the door to the vehicle.
17. Install a temporary bolt through the lower hinge pin holes.
18. Install the upper hinge pin with the pointed end up (P/N 5691595)(Figure 2,"2").
19. Install the new hinge pin retainer (P/N 15562610)(Figure 2, "3") using locking pliers and a soft faced hammer.
20. Remove the temporary bolt from the lower hinge.
21. Install the lower hinge pin with the pointed edge down (P/N 15691595)(Figure 2, "4").
22. Install a new hinge pin retainer (P/N 15562610)(Figure 2,"3").
23. Install the door hinge spring using special tool J 36604 and a 1/2 inch racheting box wrench (Figure 1, "4" and "2").
Follow steps 24 - 28 on vehicles with power door components only:
24. Connect the wiring harness connectors.
25. Install the rubber conduit through the body pillar
26. Install the retainer around the wire harness grommet.
27. Connect the receptacles to the wiring harness under the dash.
28. Install the hinge pillar trim panel (kick panel trim).
29. Connect the negative battery cable.
DOOR STOP CHECK PIN REPLACEMENT
1. Disconnect the negative battery cable.
IMPORTANT:
Apply a cloth backed tape to the door and the body pillar to guard against nicks and scratches.
CAUTION:
Before performing the following step, cover the spring with a towel to prevent the spring from dislodging and possibly causing personal injury or damage.
2. Remove the door hinge spring using special tool J 36604 and a 1/2 inch ratcheting box wrench (Figure 1, "4" and "2"). Insert the blades of the tool between the spring coils and turn the barrel nut to compress and hold the spring during removal.
3. Inspect check pin at the top where it protrudes through the top side of the upper door hinge (Figure 2, "6"). This section must be removed using a die grinder before proceeding to the next step. Cut crisscross lines in the top of the pin with the die grinder.
4. Using a center punch and hammer, gently tap the stop pin down through the hinge.
5. Insert the new stop pin (P/N 12540326) through the holes on the underside of the upper hinge and push the pin through the upper hinge holes until the top section of the pin protrudes through the hinge (Figure 2, "6").
6. Gently tap the underside of the check pin with a soft faced hammer taking care not to damage the roller assembly (Figure 1, "3").
NOTE:
In cases where gently tapping the pin will not seat the pin into the hinge, a 9 inch (23 cm) Cclamp and a spacer or socket may be used. The following procedure should be followed when using the C-clamp:
A. Position the fully opened C-clamp over the hinge with the T-handle pointing up, making sure the pad of the C-clamp is directly underneath the roller
B. Insert a socket or spacer with an opening of at least 3/8 inch (10 mm) between the top of the door hinge and the upper pad of the C-clamp. Make certain the hole in the socket or spacer is positioned directly over the opening in the hinge.
C. Carefully tighten the C-clamp, allowing the top portion of the check pin to protrude through the hinge. Tighten the C-clamp until the check pin seats in the hinge assembly.
7. Spot weld the check pin at the point where the top of the pin protrudes through the top of the hinge.
8. Install the door hinge spring using special tool J 36604 and a 1/2 inch racheting box wrench (Figure 1, "4" and "2").
9. Connect the negative battery cable.
SERVICE PARTS INFORMATION
Description Part # Qty/Door
Bushing (Lwr Hinge Lwr, Upr Hinge Upr) 17mm O.D. 15691493 2
Bushing (Lwr Hinge Upr, Upr Hinge Lwr) 18mm O.D. 15691494 2
Hinge Pin 15691595 2
Hinge Pin Retainer 15562610 2
Door Stop Check Pin 12540326 1
Parts are currently available from GMSPO.
WARRANTY INFORMATION
For vehicles repaired under warranty use:
Labor Operation Description LABOR TIME
B4062 Replace Bushing, Door Hinge Upr *
B4063 Replace Bushing, Door Hinge Lwr *
T7451 ReplaceDoorCheckPin LorR 0.4hrs.
T7452 ReplaceDoorCheckPin Both 0.6hrs.
*Use applicable labor time guide for labor times.
Note: Labor Operations are coded to base vehicle coverage in the Warranty System.