The 1982 to mid 1994 S-10 series of GM trucks, and similar vehicles are among the most durable and utilitarian vehicles GM has ever produced. They are a tribute to their designers.
These are divided into two categories, 82 mid 94, and mid 94 to current.
But, as with many good designs, some compromises were made in the interest of production, and cost. One area that this affected is the door hinge design. Which meant that they inherited the same sagging door problem as many other GM vehicles.
Here are some problems that exist with these hinges;
1) The door check, or detent that is designed to hold the door in the half open, or fully open position. It has a very powerful spring, which presses a cam against a roller. As the roller comes to rest in one of the valleys in the cam, the door is then held in position. Unfortunately the powerful spring pressure that is used to hold the door open, is also trying to push the door away from the body. And the bottom bushing in the upper door hinge wears away (illustration). At the same time the weight of the door is also pulling on the door hinge.
2) Another problem is, that the relatively small Original Equipment bushing cannot be effectively lubricated. Spraying the bushings with all manner of high tech lubricants still will not allow the lubricant to reach into the bushing, and pin contact areas. But perhaps more importantly, it cannot lubricate the flange area of the upper door hinge top bushing. This causes the flange to wear away (illustration), and the bushing then often falls out. This results in the two halves of the hinge coming into contact with each other. This is the grinding noise that is heard each time the door is closed.
3) The third problem only affects 82-94 models. It is that the door stop (illustration) is located at the bottom of the lower door hinge. The door stop is used to prevent the door from opening too far and hitting the fender. Once the bottom bushing in this hinge wears out, the steel pin wears directly against the bushing bore.
Eventually the bottom of the door hinge actually breaks in half, from repeated contact with the door stop, and the worn out bushing (illustration). The parent metal of the hinge was redesigned, and made much stronger beginning with the mid 94 models to address this problem.
We have addressed all of these issues with our new bushing design (illustration). Our steel bushings can be welded in place. This significantly increases the structural integrity of the hinge assy. Especially in the case of the 82-94 S-10 series of trucks.