Hinge Pin Replacement
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Posting Guru
Joined: Nov 2007
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From: Long Island, NY
Hinge Pin Replacement
I have a set of new pins and bushings I am going to install this weekend and I am trying to figure out how to disconnect the wires that pass from the truck to the door so I can remove the door . Will I have to pull off the door panel and disconnect every wire? Or is there one plug somewhere in the truck or door?
Hotshot
Joined: Dec 2005
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From: Chino Valley, Arizona
why remove the wires? slide a floor jack under the door, lift just the weight of the door. have someone balance the door punch out the pins move door about 2 inches replace bushings slide door back into place and set the pins.
I do them with out a helper but it is a lot harder.
I do them with out a helper but it is a lot harder.
Hotshot
Joined: Aug 2006
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why remove the wires? slide a floor jack under the door, lift just the weight of the door. have someone balance the door punch out the pins move door about 2 inches replace bushings slide door back into place and set the pins.
I do them with out a helper but it is a lot harder.
I do them with out a helper but it is a lot harder.
Use redi rod (or a long bolt)to put in the new bushings if need be
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From: Long Island, NY
I was thinking about using a floor jack like you said but I wasn't sure how well it would work out. Thought I might have to remove the whole door to get it done but ill give it a try. Will the holes have to be drilled out for the bushings? What will it take to get the old pins out? Will I be able to just punch them out? It looks like the top of the pin is peened over like a rivet.
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I disassembled my doors for the job as my helpers are 6 and 7 years old. I had other reasons to be in there as well. 250K driving around on drill sites can knock a bunch of stuff loose. First door took hours, second took minutes.
Aaon
Aaon
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From: Rogue River, OR
I scribed around the body pars and removed them. It was easier to change out the bushings/ With the scribe marks everything went right back where they were.
You will still need someone to balance the door while you are replacing the bushings.
Rog
You will still need someone to balance the door while you are replacing the bushings.
Rog
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From: Long Island, NY
Thanks for the tip. My main concern is getting the old pins out. It looks like it is going to be a pita. It looks like there wont be much room to use my 4 inch grinder to grind off the top of the pins. You scribed around the hinges removed them from the truck then removed the pin?
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From: Rogue River, OR
As I recall that is exactly what I did. IIRC the bottom of the pin is kinda "Mushroomed" out. I may have even drilled the "Mushroom head" out.
I just found it easier to pull the hinges and then place them back within the scribed lines. No further adjustment needed.
Rog
I just found it easier to pull the hinges and then place them back within the scribed lines. No further adjustment needed.
Rog
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From: Rogue River, OR
As an after thought, I recall that another member drove his truck beneath a tree, rolled down the window, threw a rope over a branch then secured the door to the rope letting the door to just kinda hang free as he didn't have a second pair of hands. Worked for him. 
Rog
Rog
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From: Long Island, NY
It looks to me like removing the hinge would make getting the pins out a lot easier. I did grind down the peened over end of one pin with the hinge still on the truck and tried to punch it out with a screwdriver but it wouldn't move. So I am going to remove the hinges kawa style so I can use my press if thats what it takes to get the old pins out. Ill get back to you and let you know how it works out. But it might have to wait till the weekend.
Hotshot
Joined: Aug 2006
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A drill bit & a punch will remove the pins nicely.A sawsall cut in the center ,hacksaw blade , cutoff wheel ...If you are going to remove the hinge from the body of the truck , take a 1/8 drill bit & drill 2 or 3 holes as far apart as possible , remove the hinge ,replace the pins & bushings . Then , put 2 or 3 (however many holes you drilled) 1/8 drill bits back in the holes you drilled to align the hinge . Without having the ability to fix anything that gets scratched,or bent .I wouldnt remove the door ,(may want to have a helper also)No matter which route you take ...
