door pin replacement
Senior User
Joined: Jul 2004
Posts: 191
Likes: 0
I did a search and found all kind of tips when I did this 3 weeks ago.
Pretty simple job. Support door, loosen bottom from door side, remove top hinge from door side, use 3/8" bit and drill off ream at bottom of top pin (Upper side on bottom pin), then use some sort of punch to knock pin out. Notice how bushings are placed. Be sure to mark door hinge positions before loosening or removing and realign when reattaching. Gently close door to test shutting.
Pretty simple job. Support door, loosen bottom from door side, remove top hinge from door side, use 3/8" bit and drill off ream at bottom of top pin (Upper side on bottom pin), then use some sort of punch to knock pin out. Notice how bushings are placed. Be sure to mark door hinge positions before loosening or removing and realign when reattaching. Gently close door to test shutting.
Fleet Owner
Joined: Mar 2003
Posts: 24,724
Likes: 74
From: Blue Hill Township
Its fairly easy. I used rope to hang the door from the rafters in the garage while it was off my truck. I also used an air cutting wheel to cut the pins in half and then pried them out. Once you dig into it you will be able to see whats going on and how easy it is.
Freshman User
Joined: Jul 2003
Posts: 43
Likes: 0
Wow, what timing
I am working on a 93 Explorer. I spent about 1/2 hour trying to get the door pins out. I gave up because of another commitment but thought I'll see if I can get some info in this forum. From what I have been reading, I think I'll cut the pin in the middle and drive the pins out. This vehicle has the typicle low hanging driver side door. If I like the results I'll do the pins and bushings on my F-150.
Freshman User
Joined: Jul 2003
Posts: 43
Likes: 0
Not removing hindges
I'm hoping I don't have to remove the hindges on the doors and just have to do the pins and bushings. If so I shouldn't have alignment issues.
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New User
Joined: Dec 2004
Posts: 15
Likes: 0
thank you for your help replacement kit ordered will reply on completion, can't
be any worse than the other projects on this vehicle. thank you again
be any worse than the other projects on this vehicle. thank you again
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Fleet Owner
Joined: Mar 2003
Posts: 24,724
Likes: 74
From: Blue Hill Township
I removed the hinge from the door so I could drill out the old bushings and so I could fit the air cutoff tool in there. Its really not that bad to re-align the door, just takes some trial and error. I think me and my buddy got the bushings installed in 15 minutes and the door lined up in 15 minutes.