Side Cargo Door is Hard to Open (Install New Hinge Pins)

This bulletin is being revised to add description information to the Parts Information table. Please discard Corporate Bulletin Number 06-08-64-032 (Section 08 -- Body & Accessories).

Some customers may comment that the side cargo doors are hard to open or are stiff.

The door hinge pins may have corroded internally.

Follow the installation instructions for Cargo Door Grease-able Hinge Pin kit below.

Important: Install the protective shield around the hinge(s) before any work is performed on the hinges.

Important: If the hinge pin will not come out using these techniques, use the J 41226 Cargo Door Hinge Pin Removal Kit with the J 41226-50 G Van Cargo Door Adapter.

1. With the door closed, drive out the top hinge pin on the cargo door. An air hammer may be required to fully drive the pin out, however, begin with a hammer and drift.
2. Remove the lower hinge pin on the same door using the same procedure as used for the top hinge.
3. Remove the door from the vehicle and place it on a cushioned workplace.
4. Remove the opposite door by driving out the hinge pins the same way as done for the first door.
5. Place the opposite door on a cushioned workplace.

Important: It is very important during steps 6 and 7 to keep the drill bit straight while passing it through the hinge pin holes in order to avoid changing the angle of the hinge pivot point.

6. Using a variable speed drill motor and a 31/64" carbide drill bit, clean the rust out of the body side hinge using care to keep the drill bit straight within the hinge.
7. Change to a ½" carbide drill bit and drill out the body side hinge pin holes to ½".
8. Apply oil to the new hinge pin bushings and install them into the body side hinges. They should fit tightly into the new ½" hole drilled into the body side hinge in step 7.

Important: The surface of the door side hinge may be corroded on the end where the retaining clip will be installed. It may be necessary to lightly grind or file this area before the door is installed.

9. Install the grease fittings into the ends of the hinge pins.
10. Install the door to the vehicle and install the top hinge pin so that the grease fitting points down and the bottom pin so the grease fitting points up. Repeat this procedure for the other door.
11. Install the retaining clips onto the ends of the hinge pins.
12. Verify the fit of the doors and adjust as required.
13. Clean any cutting oil or lubrication from the hinge surfaces.
14. Touch up all bare metal areas to help prevent future corrosion.
15. Using a grease gun, pump grease into each hinge pin until grease pushes out of the center joint of the hinge.

For vehicles repaired under warranty, use: