11-2. FRONT DOOR AND HINGE REPLACEMENT
This task covers:
a. Removal
b. Installation
Personnel Required
One mechanic
One assistant
Manual References
TM 9-2320-387-24P
General Safety Instructions
Vehicle door is extremely heavy and must be
supported during removal and installation.
Maintenance Level
Unit
TM 9-2320-387-24-2
11-4
Change 1
WARNING
Vehicle door is extremely heavy and must be supported during
removal and installation. Failure to do so may cause injury to
personnel or damage to equipment.
CAUTION
To prevent damage to armored glass, protect all exposed glass
surfaces when replacing rivets.
1.
Remove locknut (4), screw (2), and door check strap (8) from door bracket (3). Discard locknut (4).
2.
Remove sixteen capscrews (10), washers (9.1), and door (1) from A-pillar (7).
2.1.
Remove foam rubber strip (13) from rivet (11) heads.
3.
Remove fifteen rivets (11) and hinge (12) from door (1).
4.
Remove six capscrews (5), lockwashers (6), and two stop blocks (9) from door (1). Discard
lockwashers (6).
5.
Remove old adhesive completely from door (1), A-pillar (7), and hinge (12). Ensure all rust is
removed from bonded area.
1.
Install two stop blocks (9) on door (1) with six lockwashers (6) and capscrews (5). Tighten
capscrews (5) to 10 lb-ft (14 N•m).
2.
Apply adhesive to hinge (12) and door (1). Install hinge (12) on door (1) with fifteen rivets (11).
NOTE
New capscrews come with preapplied thread locking compound. If
old capscrews are to be used, mating threads must be cleaned and
sealing compound applied to threads of capscrews.
3.
Apply sealing compound to sixteen capscrews (10) (for used capscrews only). Apply adhesive to
hinge (12) and A-pillar (7). Install hinge (12) on A-pillar (7) with sixteen washers (9.1) and
capscrews (10). Tighten capscrews (10) to 37 lb-ft (50 N•m).
3.1.
Apply foam rubber strip (13) over rivet (11) heads on door (1).
4.
Install door check strap (8) on door bracket (3) with screw (2) and locknut (4).
b. Installation
a. Removal
INITIAL SETUP:
Applicable Models
M1114
Tools
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Maintenance and repair shop equipment:
automotive (Appendix B, Item 2)
Riveter tool kit (Appendix B, Item 123)
Materials/Parts
Fifteen rivets (Appendix G, Item 351)
Locknut (Appendix G, Item 166)
Six lockwashers (Appendix G, Item 202)
Closed-cell foam rubber (Appendix G, Item 23.1)
Adhesive (Appendix C, Item 2.1)
Sealing compound (Appendix C, Item 60)
