GM Truck “New Body Style” Installation

 

These installation instructions reflect the installation performed on our 1999 Chevrolet Silverado Project Vehicle. The door hinges were worn out and the door exhibited the characteristic misalignment.

Installation note: Some of these vehicles are over 20 years old. During their lifetime it is quite possible that a long handled tool has been used between the door latch and striker to actually bend the door hinges as a method of correcting door mis-alignment, or worn hinges. This method was once quite popular when welded hinges first appeared (‘82 F-body and S-10). When the door hinges are bent in this manner it is normally the upper hinge that bends, as it is the weakest. If this has ever been done to your vehicle, then it will need to be undone in order for the door to fit properly. If you encounter any alignment difficulty installing the pins, then this is most likely the cause. Try to check all the bushing bores for alignment before installing the pins. Bent hinges may require professional realignment to correct.

Step-by-Step

Familiarise yourself with the components of the kit.

  1. Remove the door panel. Disconnect and remove the wire harness from the door.

  2. Using the appropriate door support fixture, support the weight of the door.

  3. Disconnect the door check and remove the retaining bolts. Then raise the door and remove it from the vehicle.

  4. Using a cut off wheel or similar device grind off the swaged ends of the hinge pins until flush. Drive out and remove the hinge pins.  In order to help avoid damaging the hinge and simplify the process, it is suggested that the opposite side of the pins be supported, during removal. For example with a ¾inch deep well socket and heavy hammer.

  5. Remove the remains of the original bushings.

  6. Prepare the surface where the bushing flange will contact the hinge. Use a surface preparation disc or 320 grit sandpaper, to remove any traces of grease, oil, paint or corrosion.

  7. Use an acetone based solution ( Nail polish remover works very well) to remove any traces of machine oil etc, from the new bushings. Apply adhesive to the  bushing flange and body joint.

  8. Install the bushings into the hinges. Use the bolt, nut and washers to gently pull the bushings into position.

  9. Install the connector and pins. Make certain that you have identified and installed the top and bottom pins correctly.

  10. Tighten using a 9/16 inch open end wrench and a 3/8 inch 12point wrench.

  11. Lubricate the new pins and bushings with a grease gun, using the enclosed adaptor.

  12. Reattach the door, check for any alignment problems before closing the door.  The striker may require some minor adjustment.

  13. Reconnect the wire harness and install the door panel.

 

The installation is complete and periodic lubrication is recommended.

  

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