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Today I had some time, so I swapped out the door hinge pins and bushings.
I unbolted the five bolts to remove the door & then set the door on a cardboard box
with a car cover on top of the box to cushion the door. I did not disconnect the door
speaker wires so I could not just set the door out of the way.
But there was enough room to cut the door hinges in half with my jigsaw.
I burned up two blades before having the thought that a bit of lubrication
might be a good idea. Finishing off the first hinge pin and also the complete
second pin was easily & much more quickly cut using WD40 sprayed on the
cut area. I should have known that beforehand. I only use oil when drilling when
the metal is stainless or fairly thick. I just didn't think about it with the jigsaw.
I'm now wiser.
Otherwise, removing the old pins and installing the new pins and bushings went
okay. It was not a no-brainer like replacing a valve cover gasket or something, as
the pins seemed to like a combination of taps with a hammer and twisting and wiggling.
Clearly, I think, it is the bushings that wear, not the pins. Getting to the stock bushings
requires cutting the pins, so you have to replace both pin and bushings.
I used the Dorman kit. It has copper bushings, split, so it is a good idea not to
deform them too much during installation. Two of them went fast. Two went a bit
less fast, but no rocket science needed.
The new pins use lock nuts to pull the pins into the hinge. Note that the pins
with the nuts, turned to the ends of their threads, are LONGER than necessary.
If you keep turning, you will likely strip the threads on the pin or the nuts.
I am guessing this was designed so as to not deform the hinges with over-zealous
torquing. No matter. The pins don't rotate once tightened into place.
In my case, the bushings on the lower hinge were fine, but I had cut the pins
before thinking about it. If someone else is doing it, they might get away with
just replacing the top hinge's pin & bushings. I don't see why my door should
be different than anyone else's, so I am concluding that bushings on the top
hinge wear out much sooner than ones on the lower hinge.
I did run of of oomph while trying to hold the door in place and put the mounting
bolts back in place. Luckily my neighbor lady was standing there---in a nice
dress--and offered to help hold the door. I initially declined--because she
was in a dress--but she persisted. She explained that she used to help her
father work on his car. So I had help!
And after tightening the five mounting bolts and closing the door?
It closed gently and beautifully!
Thanks to all for convincing me that it was doable and pointing me
to the HOW of doing it. We did good!