09-08-64-030A

File in Section:
Bulletin No.:
Service Bulletin
Date:
08 - Body and Accessories
09-08-64-030A
June, 2013
TECHNICAL
Subject:
60/40 Side Cargo Door Binds or Will Not Open (Install New Hinge Kit)
Models:
2001-2009 Chevrolet Express Vans
2001-2009 GMC Savana Vans
Equipped with 60/40 Side Cargo Doors (RPO E24 and E26)
This bulletin has been revised to update the Parts and Warranty Information. Please discard
Corporate Bulletin Number 09-08-64-030.
Condition
Correction
Some customers may comment that the side cargo
doors bind or will not open.
Cause
2265300
2265298
The door hinges and pins may be binding or seized,
due to internal corrosion. This condition is most
commonly noted with the original hinge design shown
above.
Copyright 2013 General Motors LLC. All Rights Reserved.
Note: A new design for the body side cargo door
hinge, shown above, was developed to provide
improved resistance to corrosion. New service part kits
(which include the body and door side hinges, plates,
bolts, stop, pin and instruction sheet) were released for
the four hinge locations.
Replace the applicable upper or lower side cargo door
hinge with one of the new service replacement kits
listed in the part table below. You MUST replace both
door and body side hinges. The following installation
instructions are also supplied on the instruction sheet
within each hinge kit.
1. Remove the door trim panel for inner door access
to the hinges.
2. Remove the body pillar trim panel for interior
access to the hinges. It may be necessary to move
the front seat forward, clear of the B-pillar.
Page 2
June, 2013
Bulletin No.: 09-08-64-030A
3. Remove the door from the vehicle.
1875786
1875783
4. Cut the production body side of the door hinge
using a reciprocating saw. This is necessary to
gain access for drilling out the welds.
Important: For the forward most door (60 door), place
the backing plate on the hinge surface and move the
plate rearward 4 mm (0.16 in), then mark the three-hole
pattern.
6. Place the service backing plate on the production
hinge surface and mark the three-hole pattern.
1875785
1875787
5. Remove any excess sealer surrounding the
existing body side hinge, then tape around the
periphery of the hinge to mark the hinge
location (1).
7. Center punch the marked three-hole pattern.
Bulletin No.: 09-08-64-030A
June, 2013
1875790
8. Using the center punches as guides, drill pilot
holes using a 3 mm (1/8 in) drill bit, all the way
through the production hinge and body pillar.
9. Lightly sand the body side hinge surface to locate
the three production welds. Look for the witness
marks.
10. Center punch the three production welds for
locating the drill bit.
1875791
11. Using the center punch locations, use a 19 mm
(3/4 in) rota-broach to drill out the remainder of the
production hinge, WITHOUT drilling through the
body side hinge pillar.
12. Cut the hinge weld nuggets off.
13. Grind the pillar hinge mating surface flush.
14. Using the pilot holes drilled (through the pillar) to
center the drill bit, drill 13 mm (33/64 in) holes
through the pillar (three locations).
Page 3
15. On the rear most door (40 door), drill a 3.0 mm
(1/8 in) pilot hole completely through the welds at
each center punch mark on the body side hinge
bases.
16. Using the 3.0 mm pilot holes as guides, drill out the
three welds in the door side hinge and body side
hinge base, with a 13.0 mm (33/64 in) drill bit. The
13.0 mm holes in the pillar will provide for some
door adjustment when reinstalling the door
assembly.
17. A small amount of weld may still retain either the
hinge base to pillar or hinge base to the door. Drive
a chisel between the hinge base and door, or pillar,
to separate the hinge from either pillar or door.
18. Dress and prepare the body hinge pillar and door
as required for replacement of hinges. Ensure that
the hinge seating zones are flat to ensure good
seating for the backing plates. Also deburr holes
on the inside of the door and on the inside of the
hinge pillar.
19. Tape around the periphery of the door side hinge to
mark the hinge location.
20. Locate the approximate center of the three welds
on the door side hinge base.
21. Center punch to mark the location of the welds.
22. Drill pilot holes with a 3 mm (1/8 in) drill bit all the
way through the production hinge and the door
inner and reinforcing plate.
23. Using the 3 mm pilot holes as a guide, drill out the
three welds with a 13 mm (33/64 in) drill bit. The
13 mm holes allow for some door adjustment when
reinstalling the door assembly.
24. A small amount of weld may still retain the hinge
base to door. Drive a chisel between the hinge
base and panel to separate the hinge from
the door.
25. Dress and prepare the door as required for the
replacement hinge. Ensure that the hinge seating
zone is flat, to ensure good seating for the backing
plate, and deburr the holes on the inside of
the door.
Important: For the proper refinish materials to use,
refer to the GM Globally Approved Refinish Materials
Information (GMW-15406). The refinish materials
information is online at the GMGOODWRENCH WEB
SITE*. Printed books have been discontinued. To
access the site, follow these steps:
• Go to www.gmgoodwrench.com.
• Click on For Body Shops & Services link at
the bottom of the page.
• Click on GM Technical Repair Information.
• Click on Paint Shop tab.
*In Canada, the GM Approved Refinish Materials
booklet is also available in GM GlobalConnect by
choosing LIBRARY, SERVICE and then PAINT SHOP.
26. Paint the inner and outer surfaces of the body
hinge pillar and door, in the hinge mounting zones,
using approved refinish materials.
27. Coat the surface of the body side hinge that mates
to the hinge pillar with a medium bodied sealer.
Page 4
June, 2013
Caution: Tapping plates supplied must be used to
maintain structural integrity of the door hinge system.
DO NOT substitute with conventional washers.
28. Install the body side hinge within the scribed
location on the pillar. Use the bolts and tapping
plate supplied with the service replacement hinge
kit and tighten the hinge bolts to the recommended
preliminary torque.
Tighten
Tighten the hinge bolts to a preliminary torque of
5 Y (44 lb in).
29. Coat the surface of the door side hinge that mates
to the door with a medium bodied sealer.
30. Install the door side hinge within the scribed
location on the door. Use the bolts and tapping
plate supplied with the service replacement hinge
kit, and tighten the hinge bolts to recommended
preliminary torque.
Tighten
Tighten the hinge bolts to a preliminary torque of
5 Y (44 lb in).
31. Apply a clear silicone sealant around the entire
edge of the service hinges to prevent water leaks.
Tip: The door should not be closed completely until a
visual check is made to determine if the latch fork bolt
will correctly engage with the striker.
32. Install the door to the vehicle and align as required.
Adjust the door striker if required.
Bulletin No.: 09-08-64-030A
33. Tighten all hinge bolts to the recommended final
torque.
Tighten
Tighten all hinge bolts to a final torque of
20-25 Y (15-18 lb ft).
34. Paint the hinge assembly using approved refinish
materials.
35. Install the hinge stop from the hinge kit.
36. Reinstall the door trim and pillar trim panels.
Parts Information
Part Number
Description
Qty
19257344
Hinge Kit, Inter S/D Lwr (Dr Si)
1
19257343
Hinge Kit, Inter S/D Upr (Dr Si)
1
19257342
Hinge Kit, Rr S/D Lwr (Dr Si)
1
19257341
Hinge Kit, Rr S/D Upr (Dr Si)
1
Warranty Information
For vehicles repaired under warranty, use:
Labor
Operation
1413640
Labor
Time
Description
Intermediate Side Door Hinge
Replacement- Body Side
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
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 your GM dealer for information on whether your vehicle may benefit from the
information.
Use
Published
Labor
Operation
Time
WE SUPPORT VOLUNTARY
TECHNICIAN
CERTIFICATION