1994 to Current S-10



The installation of our door hinge repair kit is very straight forward, and is nearly identical to the normal factory recommended procedure for bushing replacement. The only difference is that our new bushings are a “press fit”, and retained with a chemical agent. They can also be welded in place if required.

Installation note: Some of these vehicles are over 20 years old. During their lifetime it is quite possible that a long handled tool has been used between the door latch and striker to actually bend the door hinges as a method of correcting door mis-alignment, or worn hinges. This method was once quite popular when welded hinges first appeared (‘82 F-body and S-10). When the door hinges are bent in this manner it is normally the upper hinge that bends, as it is the weakest. If this has ever been done to your vehicle, then it will need to be undone in order for the door to fit properly. If you encounter any alignment difficulty installing the pins, then this is most likely the cause. Try to check all the bushing bores for alignment before installing the pins. Bent hinges may require professional realignment to correct.


On our 1995 S-10 Project Vehicle which had worn out bushings.

  1. Remove the window crank handle  and arm rest screws. Detach the door panel retainers and remove the door panel while also detaching the door latch handle trim If the door has any power accessories, power windows, mirrors, etc. then remove the door panel and disconnect and remove the wire harness to those accessories.

  2. Using the appropriate tool, remove the tension spring for the door check.

  3. Remove the spring steel retainers. The retainers are made of lightweight spring steel. Remove and discard them.

  4. Remove the upper and lower hinge pins. It may be necessary to tap them out with a small punch. Normally they can be removed with pliers.

  5. Remove the door, and set it aside.

  6. Remove the bushings if they have not already fallen out. The bushings for the upper door hinge are in the body portion of hinge. The bushings for the lower door hinge are in the door portion of the hinge.

  7. Prepare the hinges to accept the new bushings. This involves removing any trace of paint, rust, grease/oil, etc. from the area of the hinges that the flange of the bushings contact, using a surface preparation disc or 180 grit sandpaper. This is done to give the chemical bonding agent a clean surface to bond to.

  8. Non-welding installation;  

·        The new bushings are designed to be a “press fit”, sometimes referred to as an “interference fit”. Use an Acetone based solution (nail polish remover works well) to remove any traces of machine oils from the busing OD, and flange contact area.  

·        Test fit the new bushings into the hinges. If any of the bushings can be fully installed by hand then they will need to be welded in place. Otherwise you can use the normal installation procedure.

·        Apply the chemical bonding agent (red Loctite) to the flange/body joint assuring that it to the full 360 degrees. Insert the bushing into the bore of the hinge. Take care to ensure that the lubricant ports on the bushings face to the rear, and positioned so that they can be lubricated after installation.  

·        Attach the bushing installation tool to pull the bushing evenly into the hinge. Once the bushing is fully installed the excess adhesive should evenly distributed around the perimeter of the flange. Repeat this procedure for the remaining bushings.

·        Re-attach the door using the new pins. Install the new pins with the upper hinge pin from bottom to top, and the lower hinge pin from top to bottom.

·        Install a retainer on the end of each pin. A 3/8” 12 point box end wrench works well for pushing the retainer down into position. If the bore in the hinge for the pin is excessively worn, then it can also be “tack welded” into position.

·        Lubricate the bushings. It is a gratifying feeling to see actual grease going into the hinges.

·        Install the door check spring using the appropriate tool.

·        Prior to closing the door for the first time, check for any misalignment or interference of the door and body to prevent any damage to the paint, or bodywork. Adjust as required.

The installation is complete.

Re-lubrication is recommended semi-annually in normal service. In commercial service, lubrication is recommended every oil change.