Originally Posted by wheatus

It seems that you can purchase lower door hinge replacements but not upper hinges. I modified my hinges to use replacable pins and bushings. To do this modification you will need: 12mm socket, ratchet, at least 3 inch extension, files or grinding tool, hammer, punch, vise, hacksaw, and a helper. (I will try and get the part numbers of the pins and bushings i used. I took my hinges to the parts store after i removed the old pins and bushings and found something close.)

1. Roll down the window, it makes the door easier to handle when removed.
2. If not equiped with power windows or locks skip to step 4.If equipped with power options you will need to remove the kickpanel and disconect the wiring.
3. Pull the wiring through the A pillar.
4. Using the ratchet, extension, and 12mm socket remove one bolt from each hinge.
5. Have your helper hold the door as you remove the last two bolts.
6. Remove the 4 bolts holding the hinges to the door shell. There should be a total of 8 bolts.
7. Place the door shell in a place where it will not get damaged.
8. Take pictures or mark the hinges top and bottom to aid reassembly later. Work on one hinge at a time so you do not mix parts.
9. Secure the hinge in a vise.
10. Using a flat file or a grinding tool, a dremel or a die grinder work well, to grind the puddle weld holding the pin. Be careful not to grind too much off of the hinge.
11. Use the punch and hammer to knock the pin out of the hinge.
12. Remove the old bushings.




13. File, drill, or grind the hinges to fit the new pins and bushings. Notice that not all of the holes are the same size, check the fitting often.



14. Line up your marks or refer to your picture for reassembly.
15. Install new bushings.
16. Install new pin.
17. Reassemble the hinge.



18. Using the hacksaw you can cut off the excess pin. (optional)
19. Repeat steps 8-18 for the other hinge.




20. Reinstall the hinges to the door shell.
21. Have helper hold the door as you mount the hinges to the body.