These installation instructions reflect the installation performed on our
1999 Chevrolet Silverado Project Vehicle. The door hinges were worn out
and the door exhibited the characteristic misalignment.
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.
yourself with the components of the kit.
the door panel. Disconnect and
remove the wire harness from the door.
the appropriate door support fixture,
support the weight of the door.
the door check and remove the retaining
bolts. Then raise the door and remove it from the vehicle.
a cut off wheel or similar device grind off
the swaged ends of the hinge pins until flush. Drive out and remove
the hinge pins. In order to help avoid damaging the hinge
and simplify the process, it is suggested that the opposite side of
the pins be supported, during removal. For example with a ¾inch deep
well socket and heavy hammer.
the remains of the original bushings.
the surface where the bushing flange
will contact the hinge. Use a surface preparation disc or 320 grit
sandpaper, to remove any traces of grease, oil, paint or corrosion.
an acetone based solution ( Nail polish remover works very well) to
remove any traces of machine oil etc, from the new bushings. Apply adhesive
to the bushing flange and body joint.
the bushings into the hinges. Use the bolt, nut and washers to
gently pull the bushings into position.
the connector and pins.
Make certain that you have identified and installed the top and bottom
using a 9/16 inch open end wrench and a 3/8 inch 12point wrench.
the new pins and bushings with a grease gun, using the enclosed
the door, check for any alignment problems before closing the
door. The striker may require some
the wire harness and install the door panel.
installation is complete and periodic lubrication is recommended.