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Just used Dorman door hinge pin and bushing repair kit #38438 and it worked very well. You will need floor jack, a friend, proper sized wrench(ratcheting closed wrench worked perfectly), oversized hammer(for weight), punch, some grease, needle nose pliers to help with e-clips
1. I would suggest marking door hinge plates mounted to door with marker on inside edge and top edge for realignment. Make sure to contact part of door and part of hinge to aid realignment. Mark door side hinge halves top and bottom. I found it essential to take off the door (four bolts on door side). This helped me while using punch and kept me away from the door while hammering and grinding.
2. grind top of pins flush with hinge brackets.
3. Use hammer and punch positioned directly over pin after grinding. You will have to hammer hard to get it out and may need to grind some to pass pin out of lower pin hole after punched through upper hole.
4. Take hinge brackets and remove remaining brass shims from hinge pin holes, Use a hammer to tap in new bushings, flat sides toward top and bottom of the brackets.
5. put some grease on the bushings and pin, then install each bracket back in the body side bracket, if too mch clearance, you will have to hammer lower bracket upward to eliminate slack, then insert pins and attach e-clips to hold. It will seem as if there isn't room for the e-clip, but the slot is close to the end.
6. now resecure door to brackets while balanced on floor jack. Get bolts finger tight, then align marks you made on the hinge and door for top then bottom, tighten each one as you align.
7. Close the door. If improperly aligned, Adjust and retighten. Mine was great on first attempt because I took plenty of time to mark before disassembly and align when reassembling.
Good luck.
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∙ 13y ago
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