REMOVAL & INSTALLATION
See Figures 1, 2 and 3
The doors are heavier than they appear. Support the door from the bottom and use a helper during removal and installation. Do not allow the door to sag while partially attached and do not subject the door to impact or twisting motions.
- Disconnect the wiring harness (if any) running between the door and the body. Carefully pull the wiring free of the body.
- Use a floor jack padded with rags or soft lumber to support the door at its lower midpoint. Use a felt tip marker to outline the hinge position on the door.
- Remove the upper and lower hinge covers if any are present. Remove the small pin holding the door check arm in place.
- Have a helper support the door, keeping it upright at all times. Remove the bolts holding the upper and lower hinge to the door. There will probably be alignment shims between the hinge and the door panel; take note of their location and placement for reassembly.
- Using two people, lift the door clear of the truck.
- The door hinge may be removed from the body if necessary (the bolts are concealed). On some models it may be necessary to use special tool MB990900-01 or equivalent. This is a specially shaped wrench built to do the job; removing the bolts will be difficult without this tool.
- If the door hinge is removed from the body, reinstall it and tighten the bolts to 25-40 ft. lbs. (35-55 Nm).
- Place the door in position and support it. Use the jack to fine tune the position until the bolt holes and matchmark (hinge outline) align.
- Apply an appropriate amount of multipurpose grease to the lower hinge roller and cam sliding area. Using engine oil, lubricate between the lower hinge pin and the roller.
- Install the hinge bolts and nuts, and the alignment shims. Tighten the bolts to 10-19 ft. lbs. (13-26 Nm).
- If all has gone well, the door should almost be in the original position. Refer to the door adjustment procedures to align the door and body. It may be necessary to loosen the hinge bolts and reposition the door; remember to retighten them each time or the door will shift out of place.
- Once adjusted, connect the door check lever and install the pin. Install the hinge covers if any were removed.
- Route the wiring harness(es) into the body and connect them to their leads.
- Test the operation of any electrical components in the door (locks, mirrors, speakers, etc.) and test drive the truck, checking the door for air leaks and rattles.