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post #1 of 43 (permalink) Old 01-17-2011, 06:58 PM Thread Starter
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new hinge vs. rebuild

My drivers side lower door hinge is in serious need of replacement. I have been weighing the pros and cons of the rebuild kit, or just purchasing a new hinge from ford. The added cost does not concern me too much, I am more concerned with making this fix as easy as possible. So, is it any less labor intensive to just change out the whole hinge with an entirely new unit?

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post #2 of 43 (permalink) Old 01-17-2011, 07:41 PM
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Changing the hinge pin is simple, so long as the holes havent egged out. With a hinge you would have to do a LOT of realigning......

John
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post #3 of 43 (permalink) Old 01-17-2011, 07:44 PM
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And replacing the hinge requires removing your dash. I got an estimate from a Ford dealer for that (I was getting an estimate on some body work anyway).. he quoted me 500.00 to replace the hinges on the drivers side door alone. Naturally I was shocked and said why so much and he said he had to remove the entire dash to get to the bolts holding the hinges in. The next guy (a local independant body shop) laughed and said he could do it for 50 bucks.. just replace the hinge pins.. guess who got the job.


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post #4 of 43 (permalink) Old 01-17-2011, 08:05 PM Thread Starter
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I thought only the upper hinge required dash removal, not the lower hinge?
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post #5 of 43 (permalink) Old 01-17-2011, 08:13 PM
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Thats probably true. But if you're going to take the time and trouble to repair/replace one hinge, take the time to do the other one as well. With the door moving up and down due to the lower hinge, the upper one can't be far behind.


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post #6 of 43 (permalink) Old 01-17-2011, 09:20 PM
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I replaced the pin in the lower only. P I B

I will buy a new hinge next time and do it right.

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post #7 of 43 (permalink) Old 01-17-2011, 09:43 PM Thread Starter
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So, replacing the entire lower hinge would be a better easier option?

Quote:
Originally Posted by rbrown View Post
I replaced the pin in the lower only. P I B

I will buy a new hinge next time and do it right.
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post #8 of 43 (permalink) Old 01-17-2011, 11:08 PM
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Even the lower hinge is a pain to replace. I did just that and it was hard to get my fingers onto the bolts. It really wasn't worth the trouble because it didn't fix the problem that I had. Now I have a maroon lower hinge on a green car.

-Randy-
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post #9 of 43 (permalink) Old 01-18-2011, 07:13 AM
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Oh snap! I had a maroon lower hinge on my teal green 94 after I painted it orange. It is fairly easy to change the lower hinge. With a friend, you shouldnt have any problems getting the door lined up. If you do them both at the same time, lining up the door is a freaking nightmare, even with reference marks. I never got the LH door totally correct on my 94 when I installed a new upper hinge/ rebuilt lower hinge.

-Rob
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post #10 of 43 (permalink) Old 01-18-2011, 09:31 AM
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Where do you get the hinge rebuild kits?

So, the door doesn't have to come off?

Al

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post #11 of 43 (permalink) Old 01-18-2011, 09:36 AM
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Quote:
Originally Posted by T6Rocket View Post
Where do you get the hinge rebuild kits?

So, the door doesn't have to come off?

Al
supercoupeperformance.com Has the kits, and no the door does not have to come off

http://www.youtube.com/watch?v=SVVozUkfDO4

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post #12 of 43 (permalink) Old 01-18-2011, 09:44 AM
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I have done it both ways and will never change an entire hinge again. I prefer the aftermarket pin kit. I bought my stuff at rockauto.
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post #13 of 43 (permalink) Old 01-18-2011, 10:47 AM
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got my pin/rebuild kit at NAPA for 4.75. easy to do. took less than an hour and i didnt have to lay under the dash to remove the hinge bolts. IMO the most productive way to do it. works as good as new

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post #14 of 43 (permalink) Old 01-18-2011, 02:57 PM Thread Starter
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so the rebuild kit is NOT an SCP only item? is the NAPA rebuild kit specific to the bird? I'm gooooooooogleing right now....
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post #15 of 43 (permalink) Old 01-18-2011, 05:29 PM
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Quote:
Originally Posted by Earl View Post
so the rebuild kit is NOT an SCP only item? is the NAPA rebuild kit specific to the bird? I'm gooooooooogleing right now....
I bought my replacement pins from Advanced..... The Help/Dorman brand have them.

Part #38438
http://www.dormanproducts.com/p-2758...ymmeid=5033992

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post #16 of 43 (permalink) Old 01-18-2011, 07:06 PM
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I got my pin kit at Advance Auto Parts

John
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post #17 of 43 (permalink) Old 01-18-2011, 08:54 PM
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I used 38410, like the tech article suggests. I think I had to drill the hinge out to use them. What are 38438?

-Rob
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post #18 of 43 (permalink) Old 01-18-2011, 09:18 PM Thread Starter
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Interesting. I was not aware the repair kit could be purchased from regular parts stores...
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post #19 of 43 (permalink) Old 01-18-2011, 11:04 PM
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Quote:
Originally Posted by Rob View Post
I used 38410, like the tech article suggests. I think I had to drill the hinge out to use them. What are 38438?
Part #38410 are listed to fit F Series pick-ups and Broncos. Probably why you had to drill out your hinges (that's interesting to know - because if the hinge holes are "egged-out", 38410 are probably REQUIRED - I dunno ).

Part #38438 are hinge pin kits listed for TBird/Cougar applications.

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post #20 of 43 (permalink) Old 01-18-2011, 11:52 PM
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If the holes are egg shaped I use the larger ones, if they are not the stock ones are fine. I have used both.
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post #21 of 43 (permalink) Old 01-19-2011, 12:30 AM
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Well looks like I will be using 38438 on the 96. I dont think the holes are hogged out too bad. Thanks for the great info. This will make the pins even easier this time!

-Rob
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post #22 of 43 (permalink) Old 01-19-2011, 12:31 AM
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you guys are gonna hate for this. i used washers as shims to re-aligned the striker w/ the lacht. mine wasn,t worn out but misaligned which causes most of the damage.

its sweet to hear how effortlessly they latch
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post #23 of 43 (permalink) Old 01-19-2011, 07:40 AM
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Quote:
Originally Posted by thunderclaw View Post
you guys are gonna hate for this. i used washers as shims to re-aligned the striker w/ the lacht. mine wasn,t worn out but misaligned which causes most of the damage.

its sweet to hear how effortlessly they latch
Yeh, mine latches easy too. However, if you pick up the end of the door with it open (it's pretty heavy), my door moves like an inch (the hinge hole is really worn). I bought the repair kit, I just haven't installed it yet. It's relatively easy to change (I have done them before). I just use a side grinder, cut the old one in half to pull top half out the top, bottom out the bottom. Then just drop the new one in, put the clip on.

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post #24 of 43 (permalink) Old 01-19-2011, 10:17 PM
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If you use shims as a band-aid be prepared for egged out holes if you wait too long to replace the pins.

Yeah, I used washers to align my drivers side door but the door was messed up not because of the pins. The door had caught the elevated corner of the front yard when I was pushing the car backwards into the driveway.

The passenger side on the other hand desperately needs new pins but for now I just avoid having to open that door.

-Randy-
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post #25 of 43 (permalink) Old 04-10-2011, 05:19 PM
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ok thread revive- I bought the dorman 38438. My holes are not "egged out" why are the bushings so much larger than the holes? Do I need to drill?

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post #26 of 43 (permalink) Old 04-10-2011, 05:41 PM
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Yup, I just did this a few days ago. I used a drill bit 2 sizes down from the 1/2" bit. I cant remember if it was 15/32" or what. You want a bit just a hair smaller than the bushing or almost right at the OD size of the bushing to install them. The dimensions are on the back of the box, but I threw them away already. Hope this helps.

EDIT: I just thought I would also mention, these pins in the 38438 kit are the perfect length and do not interfere with the bolts like the 38410 truck kits I used on previous cars would.

-Rob
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Last edited by Rob; 04-10-2011 at 05:43 PM. Reason: adding info
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post #27 of 43 (permalink) Old 04-10-2011, 06:52 PM
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Thanks Rob I'll try the 15/32 then the 31/64 bit sizes thanks again.

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post #28 of 43 (permalink) Old 09-03-2011, 02:40 PM
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Quote:
Originally Posted by V8ThunderCat View Post
If you use shims as a band-aid be prepared for egged out holes if you wait too long to replace the pins.

Yeah, I used washers to align my drivers side door but the door was messed up not because of the pins. The door had caught the elevated corner of the front yard when I was pushing the car backwards into the driveway.

The passenger side on the other hand desperately needs new pins but for now I just avoid having to open that door.
mine were not damaged just slightly off. i agree if they are damaged change them
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post #29 of 43 (permalink) Old 09-12-2011, 08:44 PM
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Found this info....not sure about pin length....but bushings are the same size... .350" ID x .480" OD.

Dorman 38438 is the "HELP" on a card.
Dorman 703-270 is in a box. About half to 1/4 the price if you google it!

Again, not sure about pin length, but the parts helper says it fits the 96.....

As for drilling the hinge, I suspect that these new bushings are over size..... I have some new bushings at home, will dig one out and measure it!

fm
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post #30 of 43 (permalink) Old 09-12-2011, 08:56 PM
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I installed 38438 on my SC and had to drill out the hinges just slightly. Honestly, the new bushings can be tapped in sans drilling, but they are too tight and the pins aren't free to spin in them. BUT when I drilled the hinge to the size recommended on the package, the bushing was -I thought- too loose in the hole. I ended up going a 64th smaller and things seemed to work well.

One thing I can say: wish I hadn't waited so long to do that job. It wasn't fun but it could have been a lot worse and the doors close great now.

Josh Keady

1994 Super Coupe ('93 5.0L swap), 1990 Tbird 3.8L, 1982 Honda CB900F, 1972 F-100 SportCustom 4x4, 1970 Chevy Custom Camper / 20
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