Bulletin No.:

Service Bulletin

Date:

23-NA-004
January, 2024

TECHNICAL
Subject:
Brand:
BrightDrop

Front Door Panel Separating
Model:

Model Year:
from

to

EV600

2022

2022

Zevo 600

2023

2023

Involved Region or Country

VIN:
from

Engine:

Transmission:

to

North America

Additional Options (RPOs)
Some customers may comment that the front (inner or outer) side door panel is
separating from the door frame.

Condition

6252115

Copyright 2024 General Motors LLC. All Rights Reserved.

Page 2

January, 2024

Bulletin No.: 23-NA-004

6252116

Cause

The causes of the condition may be due to the loss of adhesion of the bonding tape that
secures the outer panel to the door frame.

Correction

Upon verifying that the door can be repaired in a manner that will provide the proper
appearance and function, Dealers are to resecure the inner and outer door panels using
additional fasteners per the steps in the service procedure below. If the damage to the
door is determined to be not repairable, the complete door assembly must be replaced
per the PN’s listed in the GM EPC.

Bulletin No.: 23-NA-004

January, 2024

Page 3

6252117

Outboard Rivets

Page 4

January, 2024

Bulletin No.: 23-NA-004

6252118

Inboard Rivets

Bulletin No.: 23-NA-004

January, 2024

Page 5

Service Procedure
Important: Service agents must comply with all
International, Federal, State, Provincial, and/or
Local laws applicable to the activities it performs
under this bulletin, including but not limited to
handling, deploying, preparing, classifying,
packaging, marking, labeling, and shipping
dangerous goods. In the event of a conflict between
the procedures set forth in this bulletin and the
laws that apply to your dealership, you must follow
those applicable laws.
Important: This technical service bulletin (TSB) can
only be completed by BrightDrop dealers or BrightDrop
certified repair facilities who have met all BrightDrop
specific training, tool and equipment requirements.
Repairs must be performed by a technician who has
successfully completed the required training.
Note: Prior to performing the door repairs, inspect the
front side door stationary window for signs of breakage
and/or damage. This is most apparent if the door glass
has shifted within the frame causing a gap condition. If
the front stationary door does not look like it has
shifted, it is still necessary to inspect the bracket itself
per the procedure below.

6252120

1. Disengage the inner and outer upper weatherstrips
at the front side door stationary window and
inspect the upper bracket for signs of breakage or
damage.

Page 6

January, 2024

Bulletin No.: 23-NA-004

6252121

6252122

Bulletin No.: 23-NA-004

January, 2024

Page 7

2. If the bracket shows any signs of breakage or
damage, replace the front side door stationary
window. Refer to Front Side Door Stationary
Window Replacement in the Service Manual.
Outboard Side Repair Procedure
3. Remove the affected front side door and place the
door on a suitable surface with a protective
covering as to not damage/scratch the door panel.
Refer to Front Side Door Replacement in the
Service Manual.

6252124

4. Mark the vertical (A, B, C) locations along the left
side of the window, A at 54mm (2.12 in), B at 442
mm (17.4 in) the midpoint between the top and
bottom, and C at 827 mm (32.56 in).

6252123

6252125

The locations (D) where the rivets will be installed
at 13 mm (0.51 in) from the top.

Page 8

January, 2024

Bulletin No.: 23-NA-004

6252126

Mark the rivet locations along the top of the door
frame A at 80mm (3.2 in) from the left side, B at
434mm (17.09 in) from the left side, and C at
106mm (4.17 in) from the right side.

6252128

The rivet locations D should be measured at 13mm
(0.51 in) from the top.

6252129

The three rivets on the right side of the window A at
160mm (6.3 in), B at 458mm (18.03 in), and C at
756mm (29.76 in) from the top and 13 mm (0.51 in)
from the right side.

Bulletin No.: 23-NA-004

January, 2024

Page 9

6252130

6252131

6252132

Page 10

January, 2024

Bulletin No.: 23-NA-004

The three rivets at the bottom of the window frame
A at 916mm (36.06 in) and 46mm (1.81 in) from the
bottom of the window frame, B at 526mm (20.71
in), and C at 247mm (9.72 in) from the right side
and 31mm (1.22 in) from the bottom of the window
frame.

6252133

The two rivet locations in the middle of the door
frame.

6252134

Rivet A is at 507mm (19.96 in) from the bottom and
13mm (0.51 in) from the left side.

Bulletin No.: 23-NA-004

January, 2024

Page 11

6252255

Note: when attempting to install the rivets at positions
2 and 3, pull outboard on the panel at these rivet
locations for additional clearance from the main door
glass.

6252135

Rivet B at 627mm (24.68 in) from the bottom and
13mm (0.51 in) from the right side.
5. Protect the surface of each location to prevent
paint damage during the drilling process.
6. Using a 6.8mm (17/64 in) drill bit set to a depth of
10mm (using a drill stop), drill through the OUTER
panel and door frame at each of the fourteen
locations.

7. Clean the OUTER surface with an alcohol wipe to
remove any debris caused by the drilling process.
8. Insert and install a rivet in each of the fourteen
OUTER locations.
Inboard Side Repair Procedure
9. Turn the door over to access the inboard side of
the door.

Page 12

January, 2024

Bulletin No.: 23-NA-004

6252257

Measuring along the top from the left side mark A
at 138mm (5.43 in), B at 437mm (17.2 in), and C at
737mm (29.02 in) from the left side and 17mm
(0.70 in) from the top.

6252256

10. Mark the two locations from the top A at 250mm
(9.84 in) and B at 640mm (25.2 in) and 13mm (0.51
in) from the outside.
6252258

Bulletin No.: 23-NA-004

January, 2024

Page 13

6252259

Mark the vertical locations on the left side starting
from the top A at 138mm (5.43 in), B at 437mm
(17.20 in), and C at 737mm (29.02 in) from the top
at D 17mm (0.70 in) from the outside.

6252261

6252260

Mark the lower rivet location on the left side,
measuring from the lower bolt at the bottom of the
door A at 472mm (18.58 in) 17mm (0.7 in) from the
outside.

Page 14

January, 2024

11.
12.
13.
14.
15.

Bulletin No.: 23-NA-004

Mark the lower rivet location along the right side,
measuring from the lower bolt mark B at 290mm
(11.42 in) and 13mm (0.51 in) from the outside.
Protect the surface of each location to prevent
paint damage during the drilling process.
Using a 6.8mm (17/64 in) drill bit set to a depth of
10mm (using a drill stop), drill through INNER
panel and door frame at each of the ten locations.
Clean the surface with an alcohol wipe to remove
any debris caused by the drilling process.
Insert and install a rivet in each of the ten INNER
locations.
Install the affected side door. Refer to Front Side
Door Replacement in the Service Manual.

Parts Information
Causal
Part

Part
Number

Qty

X

RIVET,DOME,
0.25 SHANK DIA,
0.548 LENGTH,
0.5 OD, AA
5058, PL

09442978

24

X

WINDOW-FRT S/
D STA (RH)

85637662

1

X

WINDOW-FRT S/
D STA (LH)

85637661

1

6252262

Description

Warranty Information
For vehicles repaired under the Bumper-to-Bumper
coverage (Canada Base Warranty coverage), use the
following Labor Operation. Reference the Applicable
Warranties section of Investigate Vehicle History (IVH)
for coverage information:

6252263

Labor Operation

Description

Labor Time

*2086608

Front Door Panel Repair

2.0 hr

Add

Replace Front Stationary Window

0.3 hr

*This is a unique Labor Operation for Bulletin use only.

Bulletin No.: 23-NA-004

January, 2024

Page 15

Version

3

Modified

Released April 14, 2023
Revised May 18, 2023 – Updating Part Numbers under the Parts Information Section.
Revised January 09, 2024 - Added the 2023 BrightDrop Zevo 600.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper
service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a
job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your
vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.

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