23-NA-004 Service Bulletin/Repair Instructions

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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