Sliding Door Center Hinge Roller - May Exit the Track
NO.: 23-06-93GROUP: Body
EFFECTIVE DATE: Feb. 25, 1993
SUBJECT:
Revised Sliding Door Center and Lower Track Over-Travel Stops
MODELS:
1989-1993 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country
1987-1988 (S) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager
SYMPTOM/CONDITION:
The sliding door center hinge roller may exit the center track at the rear most end. This may result from the sliding door being allowed to repeatedly impact the stops at an abnormally high rate of travel, such as, opening the sliding door on a steep incline and allowing the door to "free-fall" into the stops. The sliding door center track over-travel stop may rotate out of the anti-rotation slot in the center track. When this occurs, the over-travel stop allows the center hinge roller to exit the rear track.
DIAGNOSIS:
Look for mis-positioned, damaged or missing sliding door center track over-travel stop bracket. Also check the upper hinge arm for being bent.
PARTS REQUIRED:
1 Bracket Package, Sliding Door 4741923
Package consists of:
1 Bracket, Sliding Door Center Track Over Travel Stop K4719498
1 Bumper, Sliding Door Center Track Over Travel Stop K4719496
1 Screw, Sliding Door Center Track Over Travel Stop Bracket K6033813
1 Arm, Sliding Door Upper Hinge K4719091
2 Screw, Sliding Door Upper Hinge Arm K6503172
PARTS REQUIRED (cont.):
1 Stop, Sliding Door Lower Hinge Arm K4719201
1 Rivet, Sliding Door Lower Hinge Arm Stop K6032881
1 Screw, Sliding Door Lower Hinge Arm Stop K153276
1 Mat, Sliding Door Quiet Hinge K4719203
1 Lubricant, Synthetic Grease # 2 MS-4977 K3769905
AR MOPAR Spray Primer and Touch Up Paint
NOTE:
THE REVISED PARTS LISTED ABOVE, ENTERED PRODUCTION AT ST. LOUIS II 8/27/92 AND AT WINDSOR 9/2/92.
REPAIR PROCEDURE:
This bulletin involves replacing the sliding door center track over-travel stop bracket and attaching screw, upper hinge arm, lower hinge stop and quiet mat.
1. Locate the revised upper hinge arm (P/N 4719091), prime and paint with the appropriate color MOPAR spray touch up paint.
2. Remove the center track cover.
A. Remove the two screws attaching the cover to the rear of the quarter panel, one is hidden behind the right tail lamp.
B. Remove the two screws attaching the cover to the quarter panel above the rear latch striker of the sliding door.
C. Slide the center track cover toward the front of the vehicle to disengage the clips holding it to the quarter panel.
3. Remove and discard the old over-travel stop bracket, bumper and screw.
4. If necessary, reinstall the center hinge roller assembly into the center track.
5. Install the sliding door center track over-travel stop bumper (P/N 4719496) into the revised center track stop bracket (P/N 4719498).
6. Install the sliding door center track over-travel stop bracket/bumper assembly with revised screw (P/N 6033813).
7. Reinstall the center track cover by reversing the procedure in step 2 above.
8. Remove and replace the upper hinge arm with revised upper hinge arm (P/N 4719091).
A. Remove the sliding door upper frame interior trim molding fasteners as necessary.
B. Remove the sliding door upper track cover fasteners as necessary.
C. Remove the upper track over travel stop.
D. Place a suitable support under the rear corner of the sliding door.
E. Unbolt the hinge from the sliding door.
F. Slide the hinge rearward until it comes out of the track.
G. With the appropriate color MOPAR spray touch up paint, color coat the primer exposed because of the hinge being removed from the sliding door.
H. Reverse preceding steps A through F to install revised upper hinge arm. Use the two new screws (P/N 6503172) in the parts package to attach the upper hinge arm to the sliding door. Align the sliding door to 6 mm (.240 in.) gap to the edge of the quarter panel and B-pillar, 7 mm (.280 in.) gap to rocker and flush across all gaps. Gaps and flushness tolerance is +/- 1 mm (.040 in.).
9. Remove the sliding door scuff plate.
10. Remove the sliding door lower hinge arm stop by drilling the rivet out with 1/4" drill bit and discard the stop. Refer to Figure 1.
11. Remove the sliding door quiet hinge mat and discard.
12. Install the revised sliding door quiet hinge mat (P/N 4719203).
13. Lubricate sliding door quiet hinge mat with synthetic # 2 lubricant (P/N 3769905). Refer to Figure 2.
14. Install the revised sliding door lower hinge arm stop (P/N 4719201) using rivet (P/N 6032881) and self drilling screw (P/N 153276).
NOTE:
IT MAY BE NECESSARY TO DISENGAGE THE FRONT EDGE OF THE QUARTER TRIM PANEL FROM THE BODY AND PULL IT FORWARD TO GAIN ADEQUATE CLEARANCE FOR THE RIVET GUN SNOUT. BE SURE THE RIVET IS FULLY SEATED AND ENGAGING THE BODY SHEET METAL BEFORE CLINCHING THE RIVET.
15. Reinstall the sliding door scuff plate.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 23-40-22-90 1.1 Hrs.
FAILURE CODE:
P8 - New Part