REAR CARGO DOOR HINGE BINDS (REPLACE PINS AND BUSHINGS)

REVISION: 12/01/95

REVISION: 12/20/95

THIS BULLETIN IS BEING REVISED TO UPDATE THE LABOR TIME AND REPAIR PROCEDURE. PLEASE DISCARD BULLETIN 361014 (GROUP REFERENCE 10 - BODY). ----------------------------------------------------------------------

REVISION: 10/09/96

THIS BULLETIN IS BEING REVISED TO ADD THE 1995-97 MODEL YEARS FOR SUBURBAN MODELS. PLEASE DISCARD CORPORATE BULLETIN NUMBER 36-10-14A (GROUP REFERENCE 10 - BODY). ----------------------------------------------------------------------

SUBJECT: REAR CARGO DOOR HINGE BINDS (REPLACE CORRODED PINS AND BUSHINGS)

MODELS: 1992-97 CHEVROLET AND GMC C/K SUBURBANS 1985-93 CHEVROLET AND GMC M/L VANS

CONDITION:

SOME CUSTOMERS MAY COMMENT THAT THE REAR CARGO DOOR HINGES BIND OR THE DOORS ARE HARD TO OPEN ON THEIR VEHICLES.

CAUSE:

REAR CARGO DOOR HINGES ARE EXPOSED TO THE ENVIRONMENTAL ELEMENTS WHICH CAUSES THE PINS AND BUSHINGS TO BECOME CORRODED IN THE HINGE HOUSING.

CORRECTION:

TO CORRECT THIS CONDITION, REPLACE THE CORRODED PINS AND BUSHINGS USING KENT MOORE TOOL # J41226.

SERVICE PROCEDURE

1. POSITION J41226-4 TEMPLATE AROUND UPPER HINGE AND TAPE TO VEHICLE.

IMPORTANT: WHEN REPAIRING A SUBURBAN, YOU MUST REMOVE .020" FROM THE TOP OF THE HINGE PINS USING A FILE OR GRINDER. (THIS WILL REMOVE THE CASE HARDNESS TO EASE THE DRILLING PROCESS.)

2. INSTALL J41226-2 SMALL DRILL GUIDE BUSHING TO J41226-1 DRILL FIXTURE.

IMPORTANT: THE DRILL GUIDE BUSHINGS ARE TWO SIDED TO FIT THE TOP OF THE DOOR HINGE PINS. MAKE SURE TO INSTALL THE PROPER END THAT BEST FITS THE HINGE PIN HEAD TO ENSURE CENTER FOR DRILLING.

3. INSTALL J41226-1 DRILL FIXTURE ONTO HINGE ASSEMBLY AND TIGHTEN LOWER SCREW TO SECURE FIXTURE TO HINGE. 4. REMOVE J41226-11 SMALL DRILL FROM THE CONTAINER AND INSTALL J41226-15 DRILL STOP COLLAR 1-3/4" FROM THE DRILL POINT.

IMPORTANT: IN MOST CASES, DRILLING THROUGH THE FIRST QUARTER OF THE HINGE SHOULD BE SUFFICIENT TO REMOVE HINGE PIN, HOWEVER SOME PINS MAY REQUIRE ADDITIONAL DRILLING AT WHICH TIME THE STOP COLLAR IS NO LONGER NEEDED.

5. ASSEMBLE J41226-11 SMALL DRILL INTO J41226-5 U-JOINT WITH THE FLAT FACING SET SCREW, AND TIGHTEN SCREW USING J41226-13 ALLEN KEY. 6. ASSEMBLE J41226-5 U-JOINT INTO DRILL MOTOR AND INSERT SMALL DRILL INTO DRILL BUSHING. 7. DRILL OUT THE UPPER PORTION OF THE HINGE PIN USING THE SMALL DRILL/STOP COLLAR. USE A SLOW DRILL SPEED AND J41226-6 CUTTING FLUID.

IMPORTANT: WHEN REMOVING THE DRILL FOR CLEANING OR OILING OF HOLE, CHIPS WILL FALL INTO HOLE CAUSING POOR DRILLING CONDITIONS. THIS CAN BE CORRECTED BY BUMPING THE DRILL THREE OR FOUR TIMES WHILE DRILLING IN THE BOTTOM OF THE HOLE TO LIFT THE CHIPS OFF THE DRILL POINT.

8. REMOVE J41226-1 DRILL FIXTURE AND REPLACE J41226-2 SMALL DRILL GUIDE BUSHING WITH J41226-3 LARGER DRILL GUIDE BUSHING.

IMPORTANT: BE SURE THE PROPER END OF BUSHING FITS THE HINGE PIN HEAD.

9. REINSTALL J41226-1 DRILL FIXTURE WITH LARGER BUSHING ONTO HINGE ASSEMBLY AND TIGHTEN LOWER SCREW. 10. REMOVE J41226-11 SMALL DRILL FROM J41226-5 U-JOINT. 11. REMOVE J41226-12 MEDIUM (.323") DRILL FROM THE CONTAINER AND ASSEMBLE DRILL INTO J41226-5 U-JOINT WITH FLAT FACING SET SCREW AND TIGHTEN. 12. POSITION MEDIUM DRILL INTO DRILL BUSHING AND DRILL UNTIL DRILL BOTTOMS IN FIRST HOLE. USE J41226-6 CUTTING FLUID. 13. REMOVE J41226-1 DRILL FIXTURE FROM HINGE ASSEMBLY. 14. INSTALL J41226-21 HINGE PIN REMOVER INTO AIR HAMMER. 15. POSITION J41226-21 PIN REMOVER INTO HINGE PIN HOLE AND REMOVE PIN FROM HINGE ASSEMBLY USING AIR HAMMER.

NOTICE: IN SOME CASES THE HINGE PIN WILL NOT MOVE FROM HINGE ASSEMBLY. IF THIS OCCURS, THE HINGE PIN WILL REQUIRE ADDITIONAL DRILLING USING THE SMALL DRILL WITHOUT THE STOP COLLAR AND THE MEDIUM DRILL.

16. REPEAT STEPS 1-15 ON LOWER HINGE ASSEMBLY BEFORE CONTINUING. 17. DISCONNECT THE DOOR STRAP AND REMOVE DOOR ASSEMBLY FROM VEHICLE. 18. REMOVE J41226-10 LARGE DRILL FROM CONTAINER AND ASSEMBLE DRILL INTO J41226-5 U-JOINT WITH FLAT FACING SET SCREW AND TIGHTEN. 19. DRILL OUT THE CENTER PORTION OF THE HINGE (CENTER SIDE OF HINGE) USING A SLOW DRILL SPEED AND J41226-6 CUTTING FLUID (FIGURE 1, ITEM 2).

IMPORTANT: THIS STEP IS REQUIRED TO PROPERLY REMOVE THE RUST AND CORROSION FROM THE HINGE ASSEMBLY AS WELL AS THE OLD HINGE PIN BUSHINGS.

20. LUBRICATE THE CENTER HINGE ASSEMBLY USING GM PART # 1050109. 21. INSTALL NEW HINGE PIN BUSHINGS USING J41226-7 BUSHING INSTALLER (FIGURE 1, ITEM 1). 22. REINSTALL THE DOOR AND ALIGN HINGE ASSEMBLIES. 23. USING A PLASTIC HAMMER, INSTALL BOTH HINGE PINS 3/4 OF THEIR LENGTH DOWN IN THE HINGE (FIGURE 1, ITEM 3). 24. INSTALL J41226-4 PROTECTIVE TEMPLATE TO UPPER HINGE. 25. REINSTALL J41226-1 DRILL FIXTURE WITH J41226-3 LARGE BUSHING ONTO HINGE ASSEMBLY AND POSITION LOWER SCREW INTO HINGE AND TIGHTEN SCREW TO SECURE FIXTURE.

IMPORTANT: J41226-1 FIXTURE AND J41226-3 BUSHING WILL ACT AS A GUIDE TO FINISH INSTALLATION OF THE HINGE PINS WHEN USING J41226-21 AND AIR HAMMER.

26. USING THE AIR HAMMER AND J41226-21, INSTALL THE HINGE PIN UNTIL HINGE PIN BOTTOMS ON UPPER HINGE BODY. 27. REMOVE FIXTURE AND REPEAT STEPS 23-26 ON LOWER HINGE. 28. APPLY TOUCH-UP PAINT WHERE NECESSARY.

PARTS INFORMATION

P/N DESCRIPTION QTY

15645336 C/K REAR CARGO DOOR HINGE PINS 5 PER PACKAGE 15598845 M/L REAR CARGO DOOR HINGE PINS 1 PER PACKAGE 15985132 REAR CARGO DOOR TEFLON COATED BUSHINGS 5 PER PACKAGE

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

WARRANTY INFORMATION

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OP DESCRIPTION LABOR TIME B6131 CARGO DOOR HINGE PINS REMOVE (LH) 1.1 HRS B6130 CARGO DOOR HINGE PINS REMOVE (RH) 1.1 HRS

IMPORTANT: LABOR OPERATION IS CODED TO BASE VEHICLE COVERAGE IN THE WARRANTY SYSTEM.

FIGURES: 1

CAPTIONS: FIGURE 1 - REAR CARGO DOOR HINGE

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.

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