924Board.org

[awilson40]

Hi Guys,
The upper hing pin on the drivers door is worn causing the door to sag. Can the hinges be removed and repaired??
Thanks

[Smoothie]

The hinge is 3 pieces: a hinge half, a hinge pin and another hinge half. You might be able to work on it by just removing the hinge pin. With some luck, just the pin will be worn and you'll only have to replace it, but; more likely, there'll be some wear on the hinge halves too. The shop manual gives the part number for only one of the hinge halves: 171.831.403 The diagram is indicating that's the half that attaches to the car body and has just one lobe. The half that attaches to the door has 2 lobes. The pin is part no.: 171.831.421 You might also be able to fix it with just bushings and a new pin.

[awilson40]

Thanks...
I've tries driving the pin out with a punch, but no luck. Is the door side of the hinge bolted or welded to the door?

[Smoothie]

The diagram shows bolt holes in the half that attaches to the body, but no bolt holes on the door half, so; my best guess is that it's welded to the door.

Here's a link to a hinge pin & bushing set from JC Whitney:
http://www.jcwhitney.com/product.jhtml;$sessionid$3JCWQ2QAAAD0XWBBLJTSFFGYEFNGMIV0?CATID=34561&_requestid=14424
It's meant for use with Chrysler, Ford and GM products, but; the silver colored pins you see in the picture are about the same diameter as the 924 pins 1/4" and the set comes with matching bushings (the one to the far left). The holes through the hinges would have to be drilled out to 21/64" to take the bushings. (I know all these details because I have one of these sets.) I used it to repair a hinge on my brothers' Ford F150 a few years ago, but; haven't had occasion to use it on the Porsche. The 1/4' pins are too long at 2 5/8", but; could be easily cut to size with a grinder.

Eastwood sells a hinge pin remover tool:
http://www.eastwoodcompany.com/cgi-bin/sgsh0101.exe?PGN=1&SKW=DIV_00%20hinge&!UID=2001122110570176&FNM=20

Northern Tool has a hinge pin popper:
http://www.northerntool.com/cgi-bin/ncommerce3/ProductDisplay?prrfnbr=369490&prmenbr=6970

(I don't have either of these.)

[Peter_in_AU]

on my '79 the bracket that the hinge bolts to is welded to the door frame and the hinge is bolted to the inside of the bracket. I had to get mine rewelded a couple of years ago the welds had parted company with the door frame.

Check that your saggies are not being caused by broken welds, those welds are supporting a lot of weight.

[ This Message was edited by: Peter_in_AU on 2001-12-22 12:49 ]

[awilson40]

Thanks for all the info guys, it really gives me something to look at. The problem is a worn pin and/or bushing and I can build whatever I need in our plant's machine shop...I just have to get the sucker apart.
That press tool looks sweet, I can build me one of those


[ This Message was edited by: awilson40 on 2001-12-22 13:46 ]

[turbo93one]

It´s easier to remove the door first and then drive the pin out. (more clearance for that hammer)

[jamez]

door hinge? rhymes with orange...

[wdb]

there are groves worn into the pins they are not going to come out easily,might try hack saw to cut the pin into a few pieces.if that does'nt work try lifting the door GENTLY with a floor jack to take the wieght off the hinge.