K 2500 Truck 4WD V8-379 6.2L DSL (1989)
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.
