How-to
1981 Ford Bronco Sagging Door Hinge Pin Replacement
A sagging door on a 1981 Ford Bronco is fixed by taking the door off, cutting out the worn hinge pins, driving out the old bushings and fitting new ones. The photos show the door drop, the pin kits, the door panel parts moved aside and the open hinges on the body.
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Step 1
Check the door against the body with the door closed, then open it and look at how far it falls. The owner reports the door had to be lifted and pushed with two well placed hands to close, and that it dropped about 5/8" once opened.
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Step 2
Get the replacement hinge pin and bushing kits before starting. The owner bought two of them at 5.49 each.
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Step 3
Remove the screw and the window crank so the door molding can be moved aside, then pull the speaker out and disconnect the speaker wiring. The owner did this to clear the wiring before taking the door off.
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Step 4
Remove the four bolts holding the door on. A 13mm socket and a ratchet are all that is needed.
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Step 5
Cut the old pins in half with a 1/8" cut off disk and separate them with a long 3/8" screwdriver, then pound the pins out and remove the other half of the hinge. Pound out the bushings, using a drill to make them slide out more easily and a 3/8" chisel to drive them out. The photo shows the hinges on the body with the door off.
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Step 6
Set the new bushings carefully, slide the hinge half back on, fit the pin and install the E clip, then rehang the door. The album's photos end with the hinge work, so no further images of the reassembly are shown.
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