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Discussion Starter #1
Has anyone done this? The FAQ says to replace the hinge pins, but no ones sells just the pins, they sell the whole hinge kit that runs $100+. Can I drill out the pins and replace them with bolts?
 

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I just replaced the lower passenger side door hinge pin, bushings, and the striker plate. Here is some additional information for those who are going to do this job.

1. If you have never replaced the bushings since the car was new, you may consider replacing the hinge too. Mine was so worn, that the bushing was completely worn through, and the pin had elongated the hole in the hinge plate. I used a 15/32 dia. drill bit, and opened up the hole, but the bushing fits in there just a hair loose.

2. In spite of this amount of wear, the upper hinge bushings had no play in them, so I am going to leave them alone.

3. When cutting the hinge pin, cut it closer to the bottom bushing, than the top. You can then take a center punch, or drift pin, and knock out the lower piece of the pin, from above. Then come up through the bottom of the lower hole, and knock out the top piece of the pin. The original pin has some knurling on it, and does not come out easily.

4. On my car, it was not necessary to make scribe marks, as it was obvious where the hinge plate was. The plate wears into the paint enough to make its' own marks.

5. For removing the door, I built a one piece, wooden support cradle to support the bottom of the door in two places. I made it the same height as the bottom of the door, and put a couple of notches in it to keep the door from falling off. Use a trolley jack to lift the car up slightly, so that you can slide the cradle under the door. Put shop rags between the door and cradle, to protect the paint. You can then slide the door away from the car, and tilt it forward, so it leans against the back edge of the fender. I then propped the door in place with a broom handle.

6. When installing the lower hinge pin, do not push it all the way down.
Leave it about 1/2" high. so that you can get the lower hinge bolt back in, and tightened. Then you can tap it the rest of the way down.

7. Part numbers from 5-Star Ford;

Hinge Pin - D9ZZ-6643030-AA
Bushing - D9OZ-6522841-C (2 req'd per hinge)
Striker Plate - F3SZ-6322008-A


Tools required:
13mm combination box wrench, Sawz-all with metal cutting blade, T50 torx head bit (for striker plate), trolley jack.
It took me about 1 hour to do the total job, including making the support cradle.

 

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Discussion Starter #3
Thanks Steve

That is the quickest, most complete response I have seen on here in a LONG time.
I know it's been asked approx 1 billion times... but do you have the number for Dan @ 5star ford?
 

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You can reach Dan at ext 230, or Max at ext. 263

Phone 1-800-866-1520
 

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