K 2500 Truck 4WD V8-379 6.2L DSL VIN C FI (1989)
Technical Service Bulletin # 02-08-64-016
Date: 020701
Body - Front Door Sags/Chucking Movement
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.
