C 3500 Truck 2WD V8-6.6L DSL Turbo VIN 1 (2002)
Front Door Hinge: Service and Repair
Front Side Door Hinge Pin and Bushing Replacement
Front Side Door Hinge Pin and Bushing Replacement
Removal Procedure
1. Remove the door. Refer to Front Side Door Replacement (See: Service and Repair/Front Side Door Replacement).
2. Remove the hinge pins from the hinge by grinding the bottom end of the pin off and driving out the remainder of the pin using a hammer and
punch.
3. Remove the old bushings from the hinges.
Installation Procedure
1. Install the hinge pin bushings (1) into the hinges.
2. Install the shorter hinge pin (3) into the bottom hole in the hinge.
3. Install the washer supplied in the kit and a standard 5/16 inch x 18 nut onto the replacement hinge pin.
4. Tap the shorter hinge pin (3) into the hinge as far as it will go.
5. Tighten the 5/16 inch x 18 nut with a hand wrench, drawing the hinge pin into the hinge until the pin is fully seated.
6. Replace the standard 5/16 inch x 18 nut with the lock nut supplied in the kit and finger tighten.
Notice: Refer to Fastener Notice (See: Service Precautions/Vehicle Damage Warnings/Fastener Notice).
7. Tighten the lock nuts.
Tighten the nuts to 19 Nm (14 lb ft).
8. Install the longer hinge pin (2) into the top hole in the hinge.
9. Install the washer supplied in the kit and a standard 5/16 inch x 18 nut onto the replacement hinge pin.
10. Tap the longer hinge pin (2) into the hinge as far as it will go.
11. Tighten the 5/16 inch x 18 nut with a hand wrench, drawing the hinge pin into the hinge until the pin is fully seated.
12. Replace the standard 5/16 inch x 18 nut with the lock nut supplied in the kit and finger tighten.
13. Tighten the lock nuts.
Tighten the nuts to 19 Nm (14 lb ft).
14. Install the door. Refer to Front Side Door Replacement (See: Service and Repair/Front Side Door Replacement).
15. Lubricate the hinge pins with Goodwrench(R) Super Lube or equivalent.
