Front Door: Service and Repair

Door Replacement

Tools Required

J 36604 Door Hinge Spring Compressor

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (C 6/7/8) Battery Negative Cable Disconnection and Connection (C 6/7/8) in Engine Electrical.
2. Remove the cowl side vent cover.
3. Remove the harness connectors from under the dash.
4. Disconnect the mirror wiring at the upper access hole in the cab (if equipped).
5. Apply cloth backed tape to the door and hinge pillar.





Caution: Before removing the spring, cover the spring with a towel to prevent the spring from flying and possibly causing damage or personal injury.

6. Remove the hinge spring. Use the J 36604 .
7. Insert the blades of the tool between the spring coils and turn the barrel nut in order to compress and hold the spring during removal.




8. Remove the retainer from the end of the upper hinge pin.
9. Remove the upper hinge pin. Use a soft-faced hammer and locking pliers.

1. Install a bolt temporarily through the upper hinges in order to hold the door in place while removing the lower hinge pin.
2. Have an assistant ready in order to support the door.

10. Remove the retainer from the end of the lower hinge pin.
11. Remove the lower hinge pin.
12. Remove the door from the vehicle.

Installation Procedure




1. Install the door to the vehicle.
2. Install the bolt temporarily through the lower hinge pin holes.
3. Install the upper hinge pin with the pointed end up.
4. Tap the upper hinge pin into place.
5. Install the new retainer to the end of the hinge pin.
6. Remove the bolt from the lower hinge.
7. Install the lower hinge pin with the pointed edge down.
8. Install a new retainer to the end of the hinge pin.




9. Install the door hinge spring. Use the J 36604 .
10. Install the harness connectors from under the dash.
11. Install the cowl side vent cover.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (C 6/7/8) Battery Negative Cable Disconnection and Connection (C 6/7/8) in Engine Electrical.