REVISED DOOR HINGE SERVICE PROCEDURE

THE FOLLOWING SUBJECT PROCEDURE SHOULD BE USED IN PLACE OF THE ONE SHOWN ON PAGE 2D-22 OF THE 1982 "S" SERIES TRUCK SHOP MANUAL (ST-369-82). FRONT DOOR HINGE SYSTEM NOTICE: THE DOOR HINGE COMPONENTS ARE IMPORTANT ATTACHING PARTS IN THAT THEY COULD AFFECT THE PERFORMANCE OF VITAL COMPONENTS AND SYSTEMS, AND/OR COULD RESULT IN MAJOR REPAIR EXPENSE. EACH PART MUST BE REPLACED WITH ONE OF THE SAME PART NUMBER OR WITH AN EQUIVALENT PART IF REPLACEMENT BECOMES NECESSARY. DO NOT USE REPLACEMENT PARTS OF LESSER QUALITY OR SUBSTITUTE DESIGN. TORQUE VALUES MUST BE USED AS SPECIFIED DURING REASSEMBLY TO ASSURE PROPER RETENTION OF THIS PART. THE DOOR SIDE HINGES ARE WELDED TO THE DOOR AND ARE NOT AVAILABLE AS SERVICE PARTS. THE FRONT DOOR HINGES ARE MADE OF STEEL AND ARE WELDED TO THE DOOR AND TO THE BODY HINGE PILLARS. NO ADJUSTMENT PROVISIONS ARE USED IN THIS TYPE SYSTEM. HOWEVER, A REMOVABLE HINGE PIN HAS BEEN PROVIDED FOR THE REMOVAL OF THE DOOR ASSEMBLY FROM THE BODY. THE SOLID STEEL HINGE PIN HAS A BARREL TYPE RETAINING CLIP AND A SERRATED SHANK NEAR THE HEAD WHICH PROVIDES A FRICTION FIT WITH THE MATING SURFACE ON THE HINGE. ALL SERVICE BODY SIDE HINGES HAVE HOLES TO PERMIT BOLT-ON INSTALLATION INTO TAPPED ANCHOR PLATES. TAPPED ANCHOR PLATES MUST BE USED INSTEAD OF NUTS AND WASHERS TO INSURE STRUCTURAL INTEGRITY WHEN REPLACING A BODY SIDE HINGE ASSEMBLY. THE FRONT DOOR UPPER HINGE HAS AN INTEGRAL TWO STAGE HOLD-OPEN FEATURE. BODY SIDE HINGE, HINGE PINS, TAPPED ANCHOR PLATES, HINGE BOLTS, BUSHINGS AND "BARREL" CLIPS ARE AVAILABLE AS SEPARATE SERVICE PARTS. FIGURE 9 IDENTIFIES THE VARIOUS PARTS OF THE FRONT DOOR HINGE SYSTEM. DOOR REMOVAL 1.ON DOORS EQUIPPED WITH POWER OPERATED COMPONENTS, PROCEED AS FOLLOWS: A.DISCONNECT BATTERY GROUND CABLE. B.REMOVE COWL KICK PANEL TRIM. C.DISCONNECT WIRE HARNESS CONNECTORS FOR POWER OPERATED COMPONENTS UNDER DASH. D.REMOVE DOOR DOME LAMP SWITCH FROM DOOR PILLAR. E.REMOVE RUBBER CONDUIT FROM PILLAR BY PUSHING THROUGH FROM KICK PANEL SIDE. 2.TAPE DOOR AND BODY PILLAR WITH CLOTH BACKED BODY TAPE. 3.REMOVE DOOR HINGE SPRING. THE RECOMMENDED METHOD FOR REMOVING THE SPRING IS WITH TOOL J-28625A (OR EQUIVALENT) DOOR HINGE SPRING COMPRESSOR TOOL. SPRING CAN ALSO BE REMOVED BY INSERTING A LONG FLAT-BLADED SCREWDRIVER UNDER PIVOT POINT OF HOLD-OPEN LINK AND OVER TOP OF SPRING. SCREWDRIVER SHOULD BE POSITIONED SO AS NOT TO APPLY PRESSURE TO HOLD-OPEN LINK. CAUTION: BEFORE PERFORMING THE FOLLOWING STEP, COVER SPRING WITH TOWEL TO PREVENT SPRING FROM "FLYING" AND POSSIBLY CAUSING PERSONAL INJURY OR DAMAGE. COVER SPRING WITH SHOP CLOTH AND LIFT SCREWDRIVER TO DISENGAGE SPRING. 4.IF REPLACEMENT HINGE PIN "BARREL" CLIPS ARE NOT AVAILABLE, SAVE THE CLIPS AS FOLLOWS: A.USING TWO SMALL SCREWDRIVERS, SPREAD CLIP ENOUGH TO MOVE CLIP ABOVE RECESS, TOWARD POINTED END OF PIN. B.AS PIN IS REMOVED, CLIP WILL "RIDE" SHANK OF PIN AND FALL FREE. C.REINSTALL CLIPS ONTO PINS BEFORE INSTALLING DOOR. 5.WITH AID OF HELPER TO SUPPORT DOOR, REMOVE LOWER HINGE PIN USING SOFT-HEADED HAMMER AND LOCKING TYPE PLIERS. HELPER CAN AID HINGE PIN REMOVAL BY RAISING AND LOWERING REAR OF DOOR. 6.INSERT BOLT INTO HOLE OF LOWER HINGE TO MAINTAIN DOOR ATTACHMENT DURING UPPER HINGE PIN REMOVAL. 7.REMOVE UPPER HINGE PIN IN SAME MANNER AS LOWER. REMOVE BOLT FROM LOWER HINGE AND REMOVE DOOR FROM BODY. DOOR INSTALLATION BEFORE INSTALLING DOOR, REPLACE HINGE PIN CLIPS OR REUSE OLD CLIPS AS EXPLAINED IN REMOVAL PROCEDURE. 1.WITH AID OF HELPER, POSITION DOOR AND INSERT BOLT IN HOLE OF LOWER HINGE. 2.UPPER HINGE PIN IS INSTALLED WITH POINTED END UP. LOWER HINGE PIN IS INSTALLED WITH POINTED END DOWN. WITH DOOR IN FULL-OPEN POSITION, INSTALL UPPER HINGE PIN USING LOCKING TYPE PLIERS AND SOFT-HEADED HAMMER. USE DRIFT PUNCH AND HAMMER TO COMPLETE PIN INSTALLATION. 3.REMOVE BOLT FROM LOWER HINGE AND INSTALL LOWER HINGE PIN. USE OF TOOL J-28625-A OR EQUIVALENT (FIGURE 10) IS RECOMMENDED METHOD FOR INSTALLING HINGE SPRING. NOTICE: IF SPRING IS INSTALLED BEFORE INSTALLING UPPER HINGE PIN, DAMAGE TO HINGE BUSHINGS MAY RESULT. 4.IF SPRING WAS REMOVED USING SCREWDRIVER, INSTALL SPRING AS FOLLOWS: A.PLACE SPRING IN TOOL J-28625-A OR EQUIVALENT (FIGURE 10). B.COMPRESS SPRING IN TOOL AND INSERT IN PROPER POSITION IN DOOR UPPER HINGE. C.REMOVE TOOL FROM DOOR HINGE. CYCLE DOOR TO CHECK SPRING OPERATION. 5.REMOVE TAPE FROM DOOR AND BODY PILLARS. 6.ON DOORS WITH POWER OPERATED COMPONENTS, INSTALL ALL PREVIOUSLY REMOVED PARTS IN REVERSE ORDER. BODY SIDE HINGES REMOVAL 1.REMOVE DOOR FROM BODY (REFER TO DOOR REMOVAL). 2.SCRIBE LOCATION OF EXISTING BODY HINGE ON BODY PILLAR. 3.CENTER PUNCH EACH OF THE FOUR WELD MARKS ON THE ORIGINAL HINGE BASE. 4.DRILL A 3MM (1/8") PILOT HOLE COMPLETELY THROUGH WELDS AT CENTER PUNCH MARKS. WHEN DRILLING OUT WELDS, DRILL ONLY DEEP ENOUGH TO PENETRATE HINGE BASE TO RELEASE HINGE FROM PANEL AS SHOWN IN FIGURE 11. 5.USING 3MM (1/8") HOLE AS A GUIDE, DRILL OUT WELDS WITH A 13MM (1/2") DRILL BIT. 6.A SLIGHT AMOUNT OF WELD MAY STILL RETAIN HINGE BASE TO PANEL. DRIVE A CHISEL BETWEEN PANEL AND HINGE BASE TO SEPARATE HINGE FROM PANEL. INSTALLATION FIGURE 9 SHOWS THE SERVICE INSTALLATION FOR HINGE ON A TYPICAL FRONT DOOR HINGE PILLAR. TAPPED ANCHOR PLATES SUPPLIED WITH SERVICE HINGES MUST BE USED TO MAINTAIN STRUCTURAL INTEGRITY OF THE DOOR HINGE SYSTEM. DO NOT SUBSTITUTE WITH NUTS AND BOLTS. 1.DRESS AND PREPARE DOOR HINGE PILLAR OR BODY FACING AS REQUIRED FOR REPLACEMENT HINGE. 2.POSITION THE SERVICE REPLACEMENT BOLT-ON HINGE WITHIN SCRIBE MARKS MADE ON BODY HINGE PILLAR AT TIME OF REMOVAL. 3.CENTER PUNCH EACH BOLT HOLE LOCATION ON BODY HINGE PILLAR. 4.USING A 13MM (1/2") DRILL BIT, DRILL HINGE ATTACHING HOLES. THE 13MM (1/2") HOLES IN THE BODY PILLAR WILL PROVIDE FOR SOME FORE AND AFT DOOR ADJUSTMENT WHEN REINSTALLING THE DOOR ASSEMBLY. 5.REMOVE DASH ATTACHMENTS AND PULL DASH OUTWARD AND SUPPORT. THIS OPERATION IS NOT NECESSARY IF ONLY LOWER HINGE IS BEING REPLACED. 6.PULL WEATHERSTRIP FROM BODY PILLAR PINCH WELD. 7.USING A HAMMER AND CHISEL, OPEN PINCH WELD ENOUGH TO INSTALL TAPPED ANCHOR PLATE (FIGURES 12 AND 13). 8.COAT SURFACE OF BODY HINGE THAT MATES TO HINGE PILLAR WITH MEDIUM BODIED SEALER. 9.PAINT HINGE AND INSTALL USING BOLTS AND TAPPED ANCHOR PLATE SUPPLIED WITH SERVICE REPLACEMENT HINGE. WHEN INSTALLING LOWER HINGE ANCHOR PLATE IT WILL BE NECESSARY TO WELD A LENGTH OF WIRE TO DASH SIDE OF ANCHOR PLATE. THIS WILL ACT AS AN AID IN ALIGNING ANCHOR PLATE WITH HOLES IN BODY HINGE PILLAR. 10.TIGHTEN HINGE BOLTS TO 20-34 N.M (14-25 LB. FT.) TORQUE. 11.CLOSE OPENING IN PINCH WELD AND SPOT WELD TO SECURE. REFINISH AS REQUIRED BEFORE INSTALLATION OF WEATHERSTRIP. 12.REMOVE DASH SUPPORT AND INSTALL DASH. 13.INSTALL WEATHERSTRIP OVER PINCH WELD. 14.INSTALL DOOR TO BODY AND ALIGN AS REQUIRED. WHENEVER HINGE HAS BEEN REPLACED AND THE DOOR REINSTALLED, THE DOOR SHOULD NOT BE CLOSED COMPLETELY UNTIL A VISUAL CHECK IS MADE TO DETERMINE IF LOCK FORK BOLT WILL CORRECTLY ENGAGE WITH STRIKER.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.