GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series (Crew) C6/C7/C8 🢒 Body 🢒 Doors 🢒 Front Side Door Hinge Pin and Bushing Replacement

Removal Procedure

    Object Number: 208789 Size: SH
  1. Remove the hinge pin retainers from the hinge pins.
  2. Grasp the lower hinge pin with a pair of locking pliers.
  3. Use a soft-faced hammer in order to drive out the lower hinge pin.
  4. Install a bolt through the lower hinges in order to temporarily hold the door in place.
  5. Grasp the upper hinge pin with a pair of locking pliers in order to remove the upper hinge pin.
  6. Use a soft-faced hammer in order to drive out the upper hinge pin.
  7. Remove the bolt from the lower hinge pin hole.
  8. With the aid of an assistant, remove the door from the vehicle.

    9. Object Number: 665763 Size: SH
  9. Remove the upper hinge pin bushings by using a suitable tool in order to remove the bushings (1) from the door.
  10. Remove the lower hinge pin bushings by using a suitable tool in order to remove the bushings (1) from the body.

Installation Procedure

    Object Number: 665763 Size: SH
  1. Install the lower hinge pin bushings using a suitable tool in order to install the bushings (1) to the body.
  2. Install the upper hinge pin bushings in using a suitable tool in order to install the bushings (1) to the door.

    3. Object Number: 208789 Size: SH
  3. With the aid of an assistant, install the door to the vehicle.
  4. Install a bolt through the lower hinges in order to temporarily hold the door in place.
  5. Drive the upper hinge pin with the pointed end up into the upper hinge using a soft-faced hammer.
  6. Remove the temporary bolt from the lower hinge.

    7. Drive the lower hinge pin with the pointed end down into the lower hinge using a soft-faced hammer .

  7. Install the hinge pin retainers to the hinge pins.