REAR CARGO DOOR INNER PANEL CRACKED OR BROKEN

SUBJECT: REAR CARGO DOOR INNER PANEL CRACKED OR BROKEN (INSTALL REINFORCEMENT PLATE AND CHECK STRAP)

MODELS: 1989-93 CHEVROLET AND GMC G-VANS

THIS BULLETIN IS BEING REVISED TO CHANGE THE WARRANTY INFORMATION. PLEASE DISCARD BULLETIN 361012.

CONDITION:

SOME OWNERS MAY COMMENT THAT THE REAR CARGO DOOR INNER PANEL HAS STARTED TO CRACK IN THE ATTACHMENT AREA OF THE DOOR CHECK STRAP BRACKET. THEY MAY ALSO COMMENT THAT THE DOOR CHECK ATTACHMENT BOLTS WILL NOT HOLD TORQUE.

CAUSE:

REPEATED OPENING AND CLOSING OF THE REAR CARGO DOOR CAN CAUSE THE INNER PANEL TO FLEX WHEN OVER-COMING THE OVER-CENTER LOAD OF THE CHECK STRAP. THIS CONDITION IS MORE APPARENT ON VEHICLES THAT ARE USED IN SITUATIONS THAT REQUIRE FREQUENT CYCLING OF THE DOORS (I.E. DELIVERY VEHICLES).

CORRECTION:

A NEW REINFORCEMENT PLATE (P/N 15988857), SIMILAR TO THE REINFORCED INSIDE DOOR PANEL CURRENTLY USED IN 1994 G-VAN PRODUCTION, HAS BEEN RELEASED TO ADDRESS THIS CONDITION. THE REINFORCEMENT PLATE SHOULD BE INSTALLED ALONG WITH A NEW CHECK STRAP (P/N 15963207). THE CHECK STRAP HAS A FOUR BOLT ATTACHMENT BRACKET THAT ALLOWS THE LOAD TO BE SPREAD OVER A LARGER AREA OF THE INNER PANEL.

SERVICE PROCEDURE:

1.REMOVE DOOR CHECK "L" PIN (FIGURE 2, ITEM 2). 2.REMOVE DOOR CHECK STRAP BRACKET FROM DOOR AND DISCARD. 3.REMOVE DOOR TRIM PANEL (IF EQUIPPED). 4.DISCONNECT REAR WINDOW DEFROSTER WIRING HARNESS (IF EQUIPPED). 5.CAREFULLY REMOVE WEATHERSTRIP FROM DOOR. 6.CUT TEMPLATE OUT ON SOLID LINE AS INDICATED (FIGURE 1). 7.BEND TEMPLATE ALONG RADIUS OF THE DOOR. NOTE: RIGHT DOOR/LEFT DOOR ORIENTATION. 8.TAPE TEMPLATE INTO POSITION. "V" NOTCH OF TEMPLATE SHOULD BE CENTERED AROUND WEATHERSTRIP FASTENER HOLE. 9.USING A CENTER PUNCH, MARK ALL FOUR CORNERS OF DOTTED LINE OF TEMPLATE. 10.INSCRIBE LINES TO CONNECT PUNCH MARKS. 11.REMOVE TEMPLATE AND CUT OUT AREA OF DOOR USING A FIBER CUTTING WHEEL. 12.POSITION, CLAMP AND WELD REINFORCEMENT PLATE (P/N 15988857) INTO PLACE (FIGURE 2, ITEM 5). 13 GRIND WELD RESIDUE AND PREPARE SURFACE FOR REPAINT. 14.INSTALL WEATHERSTRIP ON DOOR. 15.CONNECT REAR WINDOW DEFROSTER WIRING HARNESS (IF EQUIPPED). 16.INSTALL DOOR TRIM PANEL (IF EQUIPPED). 17.INSTALL DOOR CHECK STRAP BRACKET (P/N 15963207) (FIGURE 2, ITEM 1) USING FOUR BOLTS (P/N 180018) (FIGURE 2, ITEM 3). 18.INSTALL DOOR CHECK "L" PIN (FIGURE 2, ITEM 2).

SERVICE PARTS INFORMATION

P/N DESCRIPTION QTY

15988857 PLATE 1 PER DOOR 15963207 CHECK STRAP 1 PER DOOR 180018 BOLT 4 PER DOOR

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OP DESCRIPTION LABOR TIME T7701 REAR DOOR REPAIR 1.9 HR.

FOR ADDITIONAL 1.5 HR. DOOR, ADD:

NOTE: LABOR OPERATION IS CODED TO BASE VEHICLE COVERAGE IN THE WARRANTY SYSTEM.

FIGURES: 2

CAPTIONS: FIGURE 1 - REINFORCEMENT PLATE TEMPLATE FIGURE 2 - INSTALLATION OF REINFORCEMENT PLATE

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.

COPYRIGHT 1994 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.