Driver's door hinge replacement?
Senior User
Joined: Apr 2002
Posts: 265
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Driver's door hinge replacement?
The upper hinge is almost non-replaceable. You would have to remove most of the dash and electronics to get to the hinge. My Explorer actually had slop in both hinges so I replaced the lower hinge and rebuilt the top hinge. I used a hinge bolt kit from the Help! section at Autozone. I think it cost about $5. You may have to use the one for an F-150 since I don't think they carry the kit for the Explorer. I used it and it worked fine. Took a reciprocating saw and cut the factory bolt in half. Then I pried between the cut until one of the pieces came free. Then I pounded the other out with a hammer. Lining up the door so it closes properly is another story. Still working on that one...
Elder User
Joined: Dec 2000
Posts: 660
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Driver's door hinge replacement?
I had the same problem with my '91 Ex. I bought new hinges from the dealer. Be sure to pick up a can of spray paint to match and put on a couple of coats before you install. I believe the Haynes manual had some instructions on how to do this. The big thing is to mark (scribe) the hinges locations so you can install them in the same spot as the originals. Not too much of the under the dash had to be removed. I think I had to move the fuse box out of the way and take off a steel support brace that was under the dash. That was about it. You'll need various extensions and universals for your socket set. Using a floor jack to hold the door in place was helpful. I believe this is described in the Haynes manual. Be sure to use some wood and/or rags to protect the bottom of the door. There is no tricks here just some decent tools and a lot of lying on your back in the footwell. Removing the driver's seat is very helpful. All told I think it took about 3 hours. I don't know if I was lucky or good but door alignment was minimal. Maybe the scribing helped. Also, having two people was essential.
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Thisguy65
1948 - 1956 F1, F100 & Larger F-Series Trucks
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May 27, 2017 12:03 AM
Subzero68
1987 - 1996 F150 & Larger F-Series Trucks
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Aug 21, 2016 06:43 PM
2002, 2006, 96, bottom, door, driver, explorer, f150, f250, ford, hinge, instructions, lower, mountaineer, replacement
