SLIDING SIDE DOOR HARD TO OPEN AND CLOSE, NEW PARTS RELEASED

Subject: SLIDING SIDE DOOR, HARD TO OPEN/CLOSE

Model and Year: 1990-91 U VANS

THIS BULLETIN CANCELS AND SUPERSEDES DEALER SERVICE BULLETIN NO. 91-41-10, DATED AUGUST 1990. THE PROCEDURE HAS BEEN EXPANDED TO COVER ALL CORRECTIONS. ALL COPIES OF 91-41-10 SHOULD BE DISCARDED.

APPLICATION: 1990 and 1991 U-Vans prior to 1991 VIN Breakpoints

MT119199

Conditions: Some customers may comment about sliding side doors that are hard to open or close when operating;

1. from the outside of the vehicle.

2. from the inside of the vehicle.

Causes: 1. Hard opening/closing efforts from the outside may be due to:

a. binding conditions of a misaligned/misadjusted door.

b. rubber bumper missing from levers on the outside handle, (related to closing efforts, hard to unlatch from open position).

c. binding at lower latch when closing.

d. sticking of the weatherstrip to the painted surfaces of the door opening.

2. Hard opening efforts from the inside may be due to:

a. binding conditions of a misaligned/misadjusted door.

b. broken or cracked inside handle casting limiting rod travel.

c. binding at the lower latch when closing.

d. sticking of the weatherstrip to the painted surfaces of the door opening.

Diagnosis: 1. When properly aligned, the sliding side door should present a uniform even appearance regarding GAP in side view (see Figure 1). The section views in Figure 1 will provide the dimensions and tolerance ranges for flushness checks. If alignment of the door is suspect, refer to Correction #1, install new rear center roller bracket and apply a coating of silicone to the weatherstrip.

NOTE: New Rear Center Roller Bracket Assembly consists of the following: (See Figure 2)

1 - 101 96002 - Bracket, Rear Center Side door roller 1 - 101 96003 - Bracket, Rear Center Side door (door side) 1 - 101 96004 - Pin, Rear Center Side door bracket 1 - 101 86320 - Retainer, Rear Center Roller Bracket pin

2. Outside handles suspected of missing a rubber bumper may be checked by lightly moving the handle fore/aft and noting free play present. If handle has more than slight free play (1.0 to 2.0 mm), OR if the handle does not return to a "centered" position when released, rubber bumper is probably missing, refer to Correction # 2, (see Figure 3).

3. Broken/cracked inside handles may be identified by close visual inspection of the pivot area on the handle, OR if the handle does not return to a "centered" position when released, refer to Correction # 3.

4. Binding when closing may occur at the lower bracket latch and striker area. Ensure that new clip P/N 101 861 00 is installed when doing Corrections # 2 OR 3, (see Figure 4).

Correction 1: CHECK DOOR ALIGNMENT (SEE FIGURE 1) REPLACE REAR CENTER ROLLER BRACKET (SEE FIGURE 2) AND APPLY SILICONE TO WEATHERSTRIPS.

1. Obtain new rear center roller bracket parts.

Important: Prepaint the center roller and bracket parts body color.

2. Prior to assembly, lube the bushings and pin with 30 wt. motor oil or light grease. Preassemble the roller bracket and place a socket under the hinge for support and pin clearance. Use a small ball peen hammer to tap the pin into position, leaving the head of the hinge pin between 1.0 to 1.5 mm from fully seated (see Figure 2 view A) and install the retainer.

3. Open the sliding side door and mark the location of the bracket on the door side surface.

4. Use a floor jack to support the door. Pad the lower edge to protect the finish.

5. Remove the rear center roller bracket to door attaching bolts.

6. Carefully swing the rear edge of the door outward to provide clearance and slide the roller bracket forward to the end of the track.

Important: Prior to roller removal, it may be necessary to bend the front 3" of the center track upper flange SLIGHTLY OUTWARD for ease of roller removal and installation.

7. Rotate the bracket upward and remove the assembly from the track. 8. Install the new roller bracket in the track and slide rearward to the end of the track. 9. Position the bracket within the previously marked area on the door, install and tighten the bolts. 10. Remove the floor jack and CAREFULLY CLOSE DOOR TO INSPECT FOR PROPER ALIGNMENT. 11. After ensuring proper alignment, apply a light coating of silicone to the weatherstrip surfaces to reduce sticking.

ADJUSTMENT PROVISIONS:

UP / DOWN ADJUSTMENTS ARE MADE AT: ----------------------------------- 1. Lower front bracket which has slots for adjustment (REQUIRES TRIM PANEL REMOVAL). 2. Rear center roller bracket which has oversize holes for adjustment.

IN / OUT ADJUSTMENTS ARE MADE AT: ---------------------------------- 1. Upper front bracket which has slots for adjustment at door side. 2. Lower front bracket which has shims to add or remove (REQUIRES TRIM PANEL REMOVAL). Shim P/N 10122453. 3. Rear center roller bracket which has oversize holes for adjustment.

FORE / AFT ADJUSTMENTS ARE MADE AT: ----------------------------------- 1. Rear center roller bracket which has shims to add or remove. Shim P/N 10173144.

Labor Operation: B5000 Door Align B5010 Hinge, Replace add to color coat Material Allowance GB

Use applicable labor time guide for labor hours.

Correction #2: OUTSIDE HANDLE, INSTALL RUBBER BUMPER OR REPLACE HANDLE (SEE FIGURE 3) INSPECT FOR AND INSTALL CLIP AT LOWER LATCH STRIKER (SEE FIGURE 4)

1. Remove the outside handle as described in Section 10-5 of the Service Manual. 2. Install new bumper P/N 10201662 on the handle lever (see Figure 3). 3. Reinstall the handle as described in Section 10-5 of the Service Manual. 4. If lower latch striker does not have clip, install clip P/N 101 861 00 (See Figure 4).

IMPORTANT: In some cases, it may be necessary to adjust the hold open cable attachment for proper operation. This may be accomplished by loosening the screw on top of the lower roller bracket and rotating the cable attachment to remove excess slack in the cable.

Labor Operation: B5030 Outside Handle T1643 Install Clip .2Hours Trouble Code: 92

Use applicable labor time guide for labor hours.

Correction #3: REPLACE INSIDE HANDLE ASSEMBLY. INSPECT FOR AND INSTALL CLIP AT LOWER LATCH STRIKER (SEE FIGURE 4)

1. Replace the inside handle assembly as described in Section 10-5 of the Service Manual. 2. If lower latch striker does not have clip, install clip P/N 101 861 00 (see Figure 4).

IMPORTANT: In some cases, it may be necessary to adjust the hold open cable attachment for proper operation. This may be accomplished by loosening the screw on top of the lower roller bracket and rotating the cable attachment to remove excess slack in the cable.

Labor Operation: B5080 Inside Handle T1643 Install Clip .2 Hours Trouble Code: 92

Use applicable labor time guide for labor hours.

Parts are currently available from GMSPO.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those 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 a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.