04-05 Chevrolet/GMC Full Size 2500HD and 3500 Trucks Built at Flint Assembly Popping or Creaking Noise When Opening or Closing Front Doors - kw GMT800 pop creak snap click open close body check link

The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI.

Some customers may comment that the front doors on Flint built ( F in vin position #11) trucks exhibit a creaking / popping noise while opening or closing the front doors. Dealers have been replacing either check links and /or the door hinge to address this issue.

It has been determined that for Flint built trucks between March 2004 thru September, 2004, the torque guns were set to a low torque level. Technicians should be able to correct this condition by loosening and re-torquing the bolt that connects the check link to the fender to 25 Nm. Since the bolt does have loctite on it, it may be necessary to also replace the bolt.

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Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

(04-05 Chevrolet 2500HD and 3500 Trucks) and (04-05 GMC 2500HD and 3500 Trucks)

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