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Thread: Suburban Barn Door Removal?

  1. #1
    Registered User Big T's Avatar
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    Default Suburban Barn Door Removal?

    I found this Suburban barn door at a boneyard. Same color as mine, but no rust (there are positives to living in SoCal).




    My current left barn door has rust on the lower rolled edge to the point that the edge is breaking off. They want $50 for this door, but I need to remove it. I pulled two bolts from each hinge, but the hinges must be anchored by a third bolt or something as I could not get it off. I did not bring a philips screwdriver, so I could not remove the plastic trim to expose the inner portion of the hinge plate. Or do these remove by punching the hinge pin out?

    Any how to removal advice appreciated.
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  2. #2
    Registered User Suburbank2500's Avatar
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    I am not shure, but i think there is bushings also inside the hinges.

    Børge
    Last edited by Suburbank2500; 04-22-2012 at 05:18 AM. Reason: spelling
    1994 Chevrolet Suburban K2500 6,5 TD
    Custom intercooler
    Self buildt Fan tempcontroller
    Marine injectors
    Removed snorkle.
    3,5 inch exhaust
    Cat MIA
    Nr 9 resistor
    Opened Plenum
    3 pillar gauges.
    GMTD Scan tech
    A-Team Turbo
    Buddy 3 banger Installed
    K-47 filter box
    AFE dry media filter
    3.73:1 Rear

  3. #3
    OBD 1 Master Pruittx2's Avatar
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    open your door, there should be a door check of somesort,, then you have to push the pins out,, they are a Biotch! most times you have to use a torch to heat up the hinge rings,,, and use and air chisel with a pointed bit to push thru the pin. Most the ones I did, when doing body work for years,, ended up needing the hinges painted at the least. Some times you get lucky, by just poppin the pins out,, but not always. Good luck.


    1995 GMC SLT Suburban 153,000 miles
    Buddy Super chip, 4" exhaust, FTB Mod, Bosch Injectors, GU6-G80, Killer PMD Cooler FS PMD #9
    Duraterm Glows, TurboMaster, K-47 airbox, D-max fan New Mod'd clutch






  4. #4
    Registered User Big T's Avatar
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    Quote Originally Posted by Pruittx2 View Post
    open your door, there should be a door check of somesort,, then you have to push the pins out,, they are a Biotch! most times you have to use a torch to heat up the hinge rings,,, and use and air chisel with a pointed bit to push thru the pin. Most the ones I did, when doing body work for years,, ended up needing the hinges painted at the least. Some times you get lucky, by just poppin the pins out,, but not always. Good luck.
    This is in a bone yard, so I won't be able to use an air compressor and air chisel. Sounds like I'll have to go at it with the 2 lb hammer and pointed chisel. I'll bring the map gas torch.

    Tapping into your body work experience.....There is a palm sized spot on the upper right corner door where the clear coat peeled off. Can that be sanded out and redone? I have a couple of these clear coat peeling spots on the truck.

    And no I did not vote for the Socialist Obama.
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  5. #5
    Recruit
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    Are they concerned about damage you do to the area surrounding the hinges? If not, I would hack and whack the hinges out. Battery sawzall, metal cutting cirular saw, torch or similar
    98 GMC Suburban 2500 6.5 4x4 235,000 mi, FS2500, new timing chain, gears, Fluidamper & remote PMD, braided stainless oil cooler lines

    96 GMC 6.5 Suburban 1500 4x4 240,000 mi; Amsoil bypass & remote transmsision filters
    new timing chain, gears, fluidamper & remote PMD, braided stainless oil cooler lines

    95 Tahoe 2 door 4x4 6.5 240,000 mi;
    Stainless mandrel 3" exhaust, Amsoil Bypass filter, new timing chain, gears, Fluidamper, transmission, 3.73 rear end & remote PMD, braided stainless oil cooler lines

    1989 GMC Sierra 2500 2wd 5 spd get-rag trans had 108,000 mi. in 92 when the odometer broke. 7-800,000 miles on the truck. Installed a GM crate 6.5 non-turbo & FS 2500 in 2000 about 400,000 miles on the motor
    new timing chain, gears, Fluidamper & IP
    locked up and sold.

    95 Chevy C2500 xtra-cab 2wd 6.5 240,000 miles, remote PMD

    91 international 4700 low pro, spicer 6 speed, DTA 360 with 18' van box 500,000 miles plus.

    NRA Life Member for over 30 years
    Vote Freedom First

    1994 chev K3500 crew cab SRW 5 speed 4x4 230,000 miles
    PMD with heat sink. FS2500 bypass filter, The engine oil cooler lines are not leaking, Knock wood

  6. #6
    Registered User Big T's Avatar
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    I don't think they care, but I do. That would make a mess of the hinge, which is pretty stout. What I don't get is why there is two bolts to the hinge and presumably the remainder is spot welded?
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  7. #7
    Registered User NVW's Avatar
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    1/2 Acetone and 1/2 trans fluid mixed, soak it with that. If that fails I would use heat if possible. Or bigger BFH
    Leo
    * 95 GMC 3500 4x4 dually, VIN "F", 4.10 gears, 4L80/E trans, 405,000km, 3" downpipe, 4" exhaust, FSD mounted on heat sink in bumper, #9 resistor, 3 pillar gauge's, High Idle kit, Bosch marine injectors, Bosch Duraterm glow plugs, Leroy's ATT chip, ATT, GP overide, K47 airbox, FTB, Racor fuel filter, fuel pressure gauge
    * 98 Chev. 1500 4x4 VIN "S", 3.73 gears 250,000 km, (needs work)
    * 97 GMC C3500 VIN "F", 4.10 gears, 5 spd manual, 324,000 k (parts)
    * 04 Yukon Denali, 6.0, 196,000 km.
    * GMTD ScanTech
    * CarCode

  8. #8
    Just Another Diesel Guy Turbine Doc's Avatar
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    How did ya'll make out with this project, I'm in the middle of it myself on my 98 Burb, every method I've tried (soaking as above) even with Kroil (which has never failed me before) without success including "heat & beat" torch-straight punch-BFH,

    I eventually removed the doors by cutting the pin with my Dremel, now I have a short piece to drill out will grab some pics later.

    For replacement pins I went the expensive route http://www.lmctruck.com/icatalog/csd/full.aspx?Page=27 but the are the correct pin, but the quantity of bushing is incorrect 8 item (19) bushings part 31-0758 are required, I ordered (4) more bushings today dang ship/handling was more than the cost of the bushings.
    Tim (A-ACLU #29)
    98 (S)K1500,3.73 gear,4L80,Heath 4"exh,Amsoil air & bypass oil flts,Heath fan clutch,Stans Xover,pilar mtd BST/EGT/TRN,remote 12v fan tran cool,PML trans pan, PML diff cover, Hi pops, Heath PCM,Heath remote FSD, HDP Balance Flow, Heath lift pump, SSBC front calipers, EGR rear disc conversion, Goodrich brake lines, No-Slip locker, Roadmaster suspension, Lube specialist oil lines, Putnam lock & load hitch, A-team turbo.

    98 C1500 Burb Heath reflash,exhaust,ATT, Heath cooling system, Heath FSD

  9. #9
    Registered User Big T's Avatar
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    I haven't done the side doors, nor the barn doors. Never found the pins for the front doors. I have a new/used clean barn door which I cut the body side portion of the hinge using a cordless sawsall at the bone yard. Can't get that pin out, so I'll probably drill it out.

    So was the barn door pin #18 in the link? Bushing #19? Pricing? How do you order?
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  10. #10
    Just Another Diesel Guy Turbine Doc's Avatar
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    Quote Originally Posted by Big T View Post
    I haven't done the side doors, nor the barn doors. Never found the pins for the front doors. I have a new/used clean barn door which I cut the body side portion of the hinge using a cordless sawsall at the bone yard. Can't get that pin out, so I'll probably drill it out.

    So was the barn door pin #18 in the link? Bushing #19? Pricing? How do you order?
    Part #s that match the page are on page 26 http://www.lmctruck.com/icatalog/csd/full.aspx?Page=26 use the next/previous page to advance through the catalog at top of the page you can set up an online ordering profile or call the 800 # at top of the page.


    I did same thing for my donor doors and rotten doors sawed off from the truck with saws all, tomorrow weather permitting I'll grab some pictures and post them.

    Side doors are easy pull pin past retaining clip and pin comes out
    Tim (A-ACLU #29)
    98 (S)K1500,3.73 gear,4L80,Heath 4"exh,Amsoil air & bypass oil flts,Heath fan clutch,Stans Xover,pilar mtd BST/EGT/TRN,remote 12v fan tran cool,PML trans pan, PML diff cover, Hi pops, Heath PCM,Heath remote FSD, HDP Balance Flow, Heath lift pump, SSBC front calipers, EGR rear disc conversion, Goodrich brake lines, No-Slip locker, Roadmaster suspension, Lube specialist oil lines, Putnam lock & load hitch, A-team turbo.

    98 C1500 Burb Heath reflash,exhaust,ATT, Heath cooling system, Heath FSD

  11. #11
    Registered User Suburbank2500's Avatar
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    I used the pins from LMC when i replaced mine a while ago, they are good.
    I had to grind of the top of the pins, and i used a air hammer to drive it out. No mercy.
    1994 Chevrolet Suburban K2500 6,5 TD
    Custom intercooler
    Self buildt Fan tempcontroller
    Marine injectors
    Removed snorkle.
    3,5 inch exhaust
    Cat MIA
    Nr 9 resistor
    Opened Plenum
    3 pillar gauges.
    GMTD Scan tech
    A-Team Turbo
    Buddy 3 banger Installed
    K-47 filter box
    AFE dry media filter
    3.73:1 Rear

  12. #12
    Just Another Diesel Guy Turbine Doc's Avatar
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    Well I realized my error after the fact posting before in the side door thread so I copied the discussions from there to here, I've got a couple of side doors to do yet as well, but here are some pictures from my forray into barn door repair. They will be out of order as I believe the software places them in order of date/time stamp photo was taken.

    tools-1200.jpgPins out-2.jpgPins out-1-1200.jpgPin stuck in door-1200.jpgNew pin test fit-1200.jpgNew pin fit test -2-1200.jpgnew & old hinge pins & new bushing-1200.jpgLower driver side hinge-1200.jpgDrilled pin heads-3-1200.jpgDrilled pin heads-2-1200.jpgDrilled pin heads-1-1200.jpgDoor pin head removal drift-1200.jpgDoor hinge strap pin cutting locations-1200.jpgDoor hinge strap cutting-1200.jpgCut hinge pins-1200.jpgBushing partially removed-1200.jpg2 old pin bushings-1200.jpgSide by side new & old hinge pins-1200.jpg

    Tomorrow I hope to grab some pictures of the doors going back on.
    Tim (A-ACLU #29)
    98 (S)K1500,3.73 gear,4L80,Heath 4"exh,Amsoil air & bypass oil flts,Heath fan clutch,Stans Xover,pilar mtd BST/EGT/TRN,remote 12v fan tran cool,PML trans pan, PML diff cover, Hi pops, Heath PCM,Heath remote FSD, HDP Balance Flow, Heath lift pump, SSBC front calipers, EGR rear disc conversion, Goodrich brake lines, No-Slip locker, Roadmaster suspension, Lube specialist oil lines, Putnam lock & load hitch, A-team turbo.

    98 C1500 Burb Heath reflash,exhaust,ATT, Heath cooling system, Heath FSD

  13. #13
    Registered User Big T's Avatar
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    Good stuff there. So you had to use a cutting wheel to get the center section out? Then drilled and BFH's the remainder of the pins in the door side hinge?

    Also, you had to order extra bushings for each hinge?

    Although I have a rear barn door I need to install, this is completely different from the hinge pins for the forward doors.
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  14. #14
    Just Another Diesel Guy Turbine Doc's Avatar
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    Yes to the removal methods, thin cutting wheel on a Dremel tool, flex shaft would have made it easier.

    We decided it would be easier to paint without the doors on since I'm changing the color. Left my camera-camera at home so i had to resort to the cell phone camera feature but I think you get general idea of what I had to do. Yes I had to order extra bushings LMC catalog is wrong on the quantity you need a total of 4 pins & 8 bushings.

    I didn't have time to grab pictures during the side door removal, it was raining & lightning just as I finished removal barn doors are WAAAAAY harder to remove than the side doors, < 15 minutes to remove the side door both pins.

    Attached are the doors that were removed from the burb
    Attached Images Attached Images
    Tim (A-ACLU #29)
    98 (S)K1500,3.73 gear,4L80,Heath 4"exh,Amsoil air & bypass oil flts,Heath fan clutch,Stans Xover,pilar mtd BST/EGT/TRN,remote 12v fan tran cool,PML trans pan, PML diff cover, Hi pops, Heath PCM,Heath remote FSD, HDP Balance Flow, Heath lift pump, SSBC front calipers, EGR rear disc conversion, Goodrich brake lines, No-Slip locker, Roadmaster suspension, Lube specialist oil lines, Putnam lock & load hitch, A-team turbo.

    98 C1500 Burb Heath reflash,exhaust,ATT, Heath cooling system, Heath FSD

  15. #15
    Brain Damaged Diesel Junkie dangerousdave's Avatar
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    I pray I never have to do this. What lube or antisieze would you reccomend to make it easier next time?
    Not as Dangerous as I used to be Dave

    http://www.silent-warriors.com/ Veterans of America Club, member #25
    1994 Suburban 6.5TD C2500 "F", 3.73 gears, 4L80E, 265K+ miles. Heath clone bumper mount fsd, custom S&B 5x9 intake, home grown TM, Flowmaster DP and X-over, hollow soot trap, Biodiesel rated fuel lines, http://leroydiesel.com/ (Burning Oil) OPS ext. hose kit, oil cooler kit, Walbro LP. Racor pre LP filter, removed tank sock, Fuel press and boost gauges, fuel pressure gauge isolator, moved PS battery to fender, Lubrilon engine treatment, 21.2 average mpg, added air dam to improve cooling and mpg; .6mpg better now. 1 qt ND30 per 20 gallons of fuel, PS gray bottle per instructions for maintenance; keeps the injectors clean

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