Service Procedure

Follow this Service Procedure for each hinge at a time.





1. There are three types of hinges that could be installed on the vehicle; each type of hinge is equal in function and strength. To determine which type of hinge is installed, measure the outside diameter of the hinge barrel with venier calipers (Figure 1).

A Type Hinge = 18 mm diameter
B Type Hinge = 18 mm diameter

(If 18 mm, inspect the top of the bushing flange to determine the bushing material:

A Type Hinge = bronze
B Type Hinge = lubricant-impregnated mesh)

C Type Hinge = 16 mm diameter





2. Follow the instructions in Chart I for the appropriate hinge type. Procedures for drilling/lubricating, repairing, and replacing hinges are given later in this Service Procedure.

After completing inspection/repair of all 4 hinges, continue with Steps 3 through 5.





3. Affix a Hinge Lubrication Label (listed in the "Parts Information" section of this Bulletin) to the tailgate door sill (Figure 4).

4. Check operation of tailgate doors. If necessary, adjust the door latches and/or strikers as described in the appropriate Workshop Manual.

5. Affix a Campaign Label to the inside of the driver's door. Using a ball-point pen, fill in label with Campaign Number 92VO93 and dealer code.

Drill and Lubricate:

1. Open the rear doors completely.





2. Using a # 31 drill (0.120 in.) and a drill stop, drill a hole 4.5 mm deep near the weld area on the hinge. See Figure 2.

3. Spray an aerosol penetrating solvent into the hole, while moving the door through its range of travel. Continue applying the solvent until the hinge operation is smooth.

4. Lubricate the hinge through the hole.

5. Install a plug (see "Parts Information" section of this Bulletin) into the drilled hole.

Bushings and Pin Replacement





Hinge Repair Kit (listed in "Parts Information" section of this Bulletin) contains 1 pin, 2 bushings and 2 washers.

1. Support door by placing a wood block under it as described in the 1987 Trooper II (KT) Workshop Manual.

2. Remove hinge and place in a bench press or vise. Use a cloth to protect painted hinge surfaces.

3. Remove pin, using a press or a hammer and punch at the non-splined end of the pin. Separate hinge halves.

4. Remove bushings, using a punch.

5. Clean all rust and accumulated grease from inside the hinge barrel. Ensure that hinge mating surfaces are flat and clean. Lightly file if necessary (Figure 3).

6. Using an abrasive cloth or fine grit sandpaper, smooth the outer hinge surfaces which contact the barrel (see Figure 3).

7. Install new bushings and washers as shown in Figure 3.

8. Reassemble hinge halves.

9. Apply a light coating of engine oil to all surfaces of the new pin. Install pin. Top of pin should be flush with top of hinge.

10. Reinstall hinge.

Hinge Replacement

1. Support door by placing a wood block under it as described in the 1987 Trooper II (KT) Workshop Manual.

2. Remove old hinge and retain it for Warranty Parts Return.

3. Paint new hinge (listed in "Parts Information" section of this Bulletin) to match body color. Then install the new hinge.