How do you replace the door hinge on 1990 Chevy pickup?

Answer 1

First the replacment hinges are bolt on, support the door with an engine hoist through the window with the glass in the lowered position, next remove the upper and lower pins for the hinges use caution with the upper pin as the spring for the door will pop out with some force. Next remove the electrical connector in the rubber boot if you have power windows and locks there is a connector located just inside the body side of the hole. Using the hoist pull the door away and lay the door boddy side down on a thin mat on a working surface fold the mirror in and mark around the hinges with a marker. Remove the interior trim panel and the window frame and regulator and the glass, when you look inside you will see the round weld marks from the factory. Use a saws all with a good metal blade fire and resque type work best and cut between the hing and the door, use cutting oil to ease cuttiing, repeat these steps for the hinges on the body. Back on the door drill a small hole from inside the door through the center of the welds then mount your bolt on hinges line them up with your marks and mark and drill the holes, use a versa bit its coned shaped and very sharp, it can be found in lowes in the electrical dept. Next remove the kick plate in the cab and the foot brake, if you are working on the drivers side the foot brake has 3 bolts you need to remove.Remove the lowest large qube relay from the fuse block to get to the lower bolt of the foot brake.

Remove the fome inside the piller of the cab were the hinges mount, set the hing in place aline with your marks and drill 2 holes on the outer most side away from the fender, you can not drill the inner most holes the fender is in the way. Most books say to remove the hood, tire, grill, and fender you don't have to! use a dremel tool and cut the remaining 4 holes 2 on the top and 2 on the bottom in a square shape about as large as the holes in the hinge. there are 2 access holes in the piller 1 is behind the foot brake and the other is behind the kick plate bolt the hinges to the piller use a washer on the square holes. Useing the hoist hang the door and set the pins and tighten up all bolts, remove the hoist and test close the door if alinment is needed use a floor jack with a peice of wood under the door close to the hinges and apply slight pressure and losen the bolts and adjust the door then tighten em up. after all adjustments are complete reinstall the glass and regulator and trim panel. I did this my self over a week end and wanted to share the part about not removing the fender good luck and take your time it will come out fine. NOTE the bushings and pins can be replaced the auto parts stores carry them , you will only need to replace the hinges if the hole in the hing were there is no bushing has become oblonged