Tool - Door Alignment Tool
SECTION8
GROUP
83
NO.
822
DATE
Aug. -96
New door alignment tool
850
REFERENCE: TP 32395/2, SECTION 8 (81, 84) BODY AND GLASS; 850 1992- TP 32198/2, SECTION 8 (83) CENTRAL LOCKING; 850 1993
New door alignment tool
A door alignment clamp 950 1080-7 has been developed for aligning doors when installing welded hinges.
This Service Bulletin describes how to use the tool to align doors when welding hinges.
NOTE:
The method F9 on page 23 in Service Manual Section 8 (81, 84) Body and Glass 850 1992- TP 32395/2 does not apply! The tool illustrated in the Service Manual is not available.
Cross out operation F9 on page 23 i the Service Manual and write:
"Refer to Service Bulletin 83-822".
Replacing inner front door hinge
Warning!
The use of protective equipment such as safety goggles is recommended.
NOTE:
Front fender and plastic door sill trim should be removed!
Position three 0.5 mm U-shaped shims between the door and the hinge. (This allows later adjustment.)
Both hinges should be installed on the door as one piece with outer and inner sections together. Hinges should not be taken apart in this process.
Screw the door hinge assemblies into place on the door. They should be centered in the screw holes and have a straight line through both hinges.
Screw two units of 950 1080-7 into place on the underside of the rocker panel.
Adjust the tool so that the door can be placed on the supports
Position the doors on the supports. Insert hinges in existing holes in the A-post.
Align the door by turning the knobs on the tool (see arrows in previous image):
- roof, approx. 5 mm (3/16") gap
- rocker panel, approx. 12 - 13 mm (1/2") gap
- rear door, approx. 5 mm (3/16") gap.
The door should also be flush with the upper edge of the body side and the rear door.
Tack weld the inner and outer sides of the hinges using a MIG welder.
Lift off the door and remove the tool.
MIG weld the hinges and grind down the welds. Install the door and adjust if necessary using the shims. Raise/lower the rear edge of the door or adjust forward - backward.
Use the oval holes in the hinge to adjust the inward/outward position of the door.
Replacing inner rear door hinge
Screw the door hinge assemblies into place on the door.
The method is the same as for the front door except that the door is aligned with the rear fender instead of the rear door.