Cypher
27-11-2011, 03:22 PM
So I've had a problem with my drivers side door for a while now where it drops about 5-10mm after opening. This means that sometimes the door doesn't close properly without having to lift it while closing. Also causes problems with the door trim catching on the sill when opening.
You can get door hinge repair kits from Rock Auto for quite cheap, so I decided to have a crack at fixing my problem. I did some research as to how to actually fit the new pins and the easiest way I found would be to do it without removing the door as that would require re-alignment of the hinges and striker plate.
The tools I used were a Dremel/rotary tool with cutting wheels and flex shaft, a hammer and various drifts and a flat headed screwdriver.
Here's what the hinge pin kits look like, you need two per door and I got four as I plan to do the passengers door at some stage.
http://i.imgur.com/XnoITl.jpg (http://imgur.com/XnoIT)
The first step is to support the weight of the door. The scissor jack worked out quite well later on for adjusting the height of the door to get the new hinge pins in.
http://i.imgur.com/3BaWdl.jpg (http://imgur.com/3BaWd)
It's helpful at this stage to undo the door check strap, this is the bit that stops the door opening too far and holds the door open. Simply punch out the pin and then move it aside.
Looking at the door hinge, the pin is actually covered by a plastic sleeve so first step is to remove this. I cut into it a bit with the dremel and then attacked it with hammer and screwdriver to get it off.
http://i.imgur.com/NslfGl.jpg (http://imgur.com/NslfG)
Plastic sleeve removed, starting to cut hinge pin. You need to cut at an angle otherwise there's not enough room to maneuver the cutting disc.
http://i.imgur.com/R4EMgl.jpg (http://imgur.com/R4EMg)
Cutting complete. Try not to cut into anything else like I did.
http://i.imgur.com/DfjnLl.jpg (http://imgur.com/DfjnL)
The bottom section should come out easily with a few taps.
http://i.imgur.com/Wnmtll.jpg (http://imgur.com/Wnmtl)
http://i.imgur.com/7klQKl.jpg (http://imgur.com/7klQK)
The top section is a little more stubborn but I used a suitable bolt and it came out with a few decent taps, its a bit awkward to get a decent swing on the hammer though.
http://i.imgur.com/XGaHql.jpg (http://imgur.com/XGaHq)
Once the splined section is clear it comes out easier.
http://i.imgur.com/bS5AMl.jpg (http://imgur.com/bS5AM)
Old hinge pin removed
http://i.imgur.com/OINPGl.jpg (http://imgur.com/OINPG)
http://i.imgur.com/H0XeRl.jpg (http://imgur.com/H0XeR)
So the next part is a little light on pictures as it got difficult to juggle the weight of the door and hold the new bushes in place. A second set of hands wouldn't go astray for this. Essentially repeat the above steps to cut out the bottom hinge pin. Once this is free you will need to remove the old metal bushes from the hinges.
Carefully pull the door away from the car, make sure not to go too far as you don't want to put any tension on the wiring loom. Using the flat blade screwdriver and hammer punch out the old bushes top and bottom, two per hinge. With these removed you can put the new bushes in which can be tricky because the ones on the bottom like to fall out quite easily. Some grease would probably hold them in but I managed to luck it all together without them falling out. Once they are in place move the door back onto the hinges. I used a screwdriver in the top hinge to help line things up.
With the new bushes in I took this opportunity to cover everything with lithium grease. Now you'll need to put in the new plastic sleeves. They may be a little too long to fit, I shaved a little off mine and tapped them in with a hammer, again using a screwdriver to help line things up.
The second person comes in handy here as well, otherwise taking the weight of the door with the window frame on your shoulder line up the hinge and slot the new pin in. This is also where adjusting the scissor jack came in handy. It took a bit of aligning and a few taps to get the new pin seated in both hinge holes. Do the same for the bottom and you're done!
http://i.imgur.com/ikfEel.jpg (http://imgur.com/ikfEe)
I'd say you're supposed to hammer the pins all the way home, but mine were mighty tight and even after bashing on them with a drift and BFH they wouldn't go in any further. At a later date I may pop them out and grind out the holes slightly. There is a circlip that goes on the bottom of the pins to stop them from working loose. Put the pin for the door check strap back in and give it a test close and open.
My problem was completely fixed. The door opens and closes perfectly now, very happy! :D
You can get door hinge repair kits from Rock Auto for quite cheap, so I decided to have a crack at fixing my problem. I did some research as to how to actually fit the new pins and the easiest way I found would be to do it without removing the door as that would require re-alignment of the hinges and striker plate.
The tools I used were a Dremel/rotary tool with cutting wheels and flex shaft, a hammer and various drifts and a flat headed screwdriver.
Here's what the hinge pin kits look like, you need two per door and I got four as I plan to do the passengers door at some stage.
http://i.imgur.com/XnoITl.jpg (http://imgur.com/XnoIT)
The first step is to support the weight of the door. The scissor jack worked out quite well later on for adjusting the height of the door to get the new hinge pins in.
http://i.imgur.com/3BaWdl.jpg (http://imgur.com/3BaWd)
It's helpful at this stage to undo the door check strap, this is the bit that stops the door opening too far and holds the door open. Simply punch out the pin and then move it aside.
Looking at the door hinge, the pin is actually covered by a plastic sleeve so first step is to remove this. I cut into it a bit with the dremel and then attacked it with hammer and screwdriver to get it off.
http://i.imgur.com/NslfGl.jpg (http://imgur.com/NslfG)
Plastic sleeve removed, starting to cut hinge pin. You need to cut at an angle otherwise there's not enough room to maneuver the cutting disc.
http://i.imgur.com/R4EMgl.jpg (http://imgur.com/R4EMg)
Cutting complete. Try not to cut into anything else like I did.
http://i.imgur.com/DfjnLl.jpg (http://imgur.com/DfjnL)
The bottom section should come out easily with a few taps.
http://i.imgur.com/Wnmtll.jpg (http://imgur.com/Wnmtl)
http://i.imgur.com/7klQKl.jpg (http://imgur.com/7klQK)
The top section is a little more stubborn but I used a suitable bolt and it came out with a few decent taps, its a bit awkward to get a decent swing on the hammer though.
http://i.imgur.com/XGaHql.jpg (http://imgur.com/XGaHq)
Once the splined section is clear it comes out easier.
http://i.imgur.com/bS5AMl.jpg (http://imgur.com/bS5AM)
Old hinge pin removed
http://i.imgur.com/OINPGl.jpg (http://imgur.com/OINPG)
http://i.imgur.com/H0XeRl.jpg (http://imgur.com/H0XeR)
So the next part is a little light on pictures as it got difficult to juggle the weight of the door and hold the new bushes in place. A second set of hands wouldn't go astray for this. Essentially repeat the above steps to cut out the bottom hinge pin. Once this is free you will need to remove the old metal bushes from the hinges.
Carefully pull the door away from the car, make sure not to go too far as you don't want to put any tension on the wiring loom. Using the flat blade screwdriver and hammer punch out the old bushes top and bottom, two per hinge. With these removed you can put the new bushes in which can be tricky because the ones on the bottom like to fall out quite easily. Some grease would probably hold them in but I managed to luck it all together without them falling out. Once they are in place move the door back onto the hinges. I used a screwdriver in the top hinge to help line things up.
With the new bushes in I took this opportunity to cover everything with lithium grease. Now you'll need to put in the new plastic sleeves. They may be a little too long to fit, I shaved a little off mine and tapped them in with a hammer, again using a screwdriver to help line things up.
The second person comes in handy here as well, otherwise taking the weight of the door with the window frame on your shoulder line up the hinge and slot the new pin in. This is also where adjusting the scissor jack came in handy. It took a bit of aligning and a few taps to get the new pin seated in both hinge holes. Do the same for the bottom and you're done!
http://i.imgur.com/ikfEel.jpg (http://imgur.com/ikfEe)
I'd say you're supposed to hammer the pins all the way home, but mine were mighty tight and even after bashing on them with a drift and BFH they wouldn't go in any further. At a later date I may pop them out and grind out the holes slightly. There is a circlip that goes on the bottom of the pins to stop them from working loose. Put the pin for the door check strap back in and give it a test close and open.
My problem was completely fixed. The door opens and closes perfectly now, very happy! :D