Sedona Sliding Door Center Bracket Repair

[Inky]

SPECIFICATIONS: This is specific to the 2002 Kia Sedona but likely applies to other years as well.

NOTE: On the center roller assembly of the side sliding doors on the Sedona, Kia used plastic bushings on the upright posts which fit into the track. These are insufficient for the repeated sliding of the heavy door and will eventually break. After the first one breaks, the door will begin to bind. After the second one fails, the binding will noticeably increase.

PARTS NEEDED: 2 Replacement Bushings (Metal, NOT Plastic), Grease -- If you decide to replace the entire roller assembly, the part number for the right side is 0K552 72230G. I assume, though do not know for sure, that the part number is similar or the same for the left side.

TOOLS NEEDED: Socket Wrench (Ratchet), 1/2" Socket, Socket Wrench Extension (helpful but not required), Phillips Screwdriver, Cement Blocks and/or Wood to support rear of sliding door

TIME: 45 minutes to 1 hour

PROCESS:
1. Place supports near outside of door to be repaired.

2. With door closed and working from inside of vehicle, remove plastic trim screw holding panel over the bolts securing the roller assembly.

http://www.kia-forums.com/attachment...9&d=1149308323

3. Remove the plastic panel.

4. Remove the three bolts securing the roller assembly. Screw (blue arrow) does not need to be removed.

http://www.kia-forums.com/attachment...5&d=1149308276

5. From outside the vehicle, fully open the door.

Even with the bolts removed, the roller assembly will probably still support the door as it is opened. However, to be on the safe side, SUPPORT THE REAR OF THE DOOR AS SOON AS POSSIBLE.

6. Use supports to prop rear of sliding door. You may want to use a piece of carpet or cloth to prevent the supports from scratching the paint.

7. After ensuring there is adequate space between the body and the door, open the rear side window.

8. Remove the stop at the end of the center track (secured by one screw).

http://www.kia-forums.com/attachment...1&d=1149308340

9. Loosen the rubber gasket between the door and the roller assembly.

http://www.kia-forums.com/attachment...0&d=1149308331

10. Remove the roller assembly from the door and the track.

http://www.kia-forums.com/attachment...8&d=1149308316

http://www.kia-forums.com/attachment...2&d=1149308358

http://www.kia-forums.com/attachment...3&d=1149308370

http://www.kia-forums.com/attachment...4&d=1149308378

11. If either plastic bushing remains, remove it.

12. Completely clean the roller assembly with hot soapy water and a soft brush.

13. Dry.

http://www.kia-forums.com/attachment...7&d=1149308308

14. Install new bushings by slipping onto roller assembly's upright posts.

http://www.kia-forums.com/attachment...6&d=1149308294

15. Thoroughly grease bushings (inside and out), roller, and other moving portions of the roller assembly.

16. Reinstall the roller assembly onto the door (reverse of 9 & 10).

17. Reinstall end of track stop (reverse of 8).

18. Slowly close door, being careful to support the rear portion and keep the bracket in place while sliding. NOTE: Since things don't quite line up yet, the sliding at this point may be a bit rough.

BE CAREFUL NOT TO SMASH YOUR FINGERS AS THE DOOR COMES TO A CLOSE.

19. From inside the vehicle, note if the door is fully closed. If it isn't, open slightly and reclose.

20. Align roller assembly and reinsert one bolt at a time, tightening until nearly snug.

21. Once all bolts are in place, snug each in order (bottom rear, top rear, front).

22. Once all bolts are snug, tighten each completely (bottom rear, top rear, front).

23. Grease inside of top track (front, top, back) and bottom track (front, bottom, back).

24. Replace panel (reverse of 3) and trim screw (reverse of 2).

25. Open and close door several times to distribute grease.

Thanks to ndiarch for providing the exact part name and number. He has included additional images on Page 2 of this thread.

[pepper]

Nice work, I'm sure more and more of us will be doing just this as ours get older. Thanks.

[Inky]

Thanks, Pepper. I've only done the left door so far. The right door is okay. I think because, in my case, the left door is on the driver's side, it was opened and closed a lot more than the other one.

This was actually the subject of a TSB so, for those still under warranty, it should be free.

For the rest us, it's not a terribly big ordeal.

[Milo]

I am having a difficult time finding metal bushings. I have gone to the dealerships and they only have plastic bushings and oly sell them in kits with the whole bracket. Does anyone know where I can find these parts? Thanks.

[ChrisG]

I had this repair made under warranty - except the door wasn't aligned properly when they put it back together. Rather than taking it back for the fix, I found these instructions and loosened/retightened the bolts in step four to fix the problem.

Thanks kia-forums.

[hongo]

My 02 Sedona's right side sliding door can not be closed tightly if the right side front door is closed. But if the right side front door is open then the sliding door can be closed tightly without problems. Is this problem due to failed bushings? Thanks.

[cqt]

Thanks to Inky ...

[Inky]

Originally Posted by Milo

I am having a difficult time finding metal bushings. I have gone to the dealerships and they only have plastic bushings and oly sell them in kits with the whole bracket. Does anyone know where I can find these parts? Thanks.

The ones I used were cut from metal tubing. I'm not sure the size, unfortunately. If you remove the rear bracket, you should be able to take it to a local hardware store to match the size. Remember there is a bit of a gap between the bushings and the posts onto which they fit.

[Inky]

Originally Posted by hongo

My 02 Sedona's right side sliding door can not be closed tightly if the right side front door is closed. But if the right side front door is open then the sliding door can be closed tightly without problems. Is this problem due to failed bushings? Thanks.

This sounds like some kind of alignment issue with one of the doors on that side. I'm not saying it is not an issue with the bushings. However, both of the bushings on my left sliding door were gone and, while the door didn't slide smoothly, it did close properly.

[Inky]

Originally Posted by ChrisG

I had this repair made under warranty - except the door wasn't aligned properly when they put it back together. Rather than taking it back for the fix, I found these instructions and loosened/retightened the bolts in step four to fix the problem.

Thanks kia-forums.

I'm glad you, cqt, and others found the instructions helpful. If anyone ever has a question on them, please send me a PM.