Door Sag/Hard Close Procedure
Derek O'Banion
Introduction
After more than a decade the doors begin to sag. There are several symptoms of this:
  1. Back of door does not line up with lines of body
  2. Worn door striker (located on body in back of door jam)
  3. Difficult to close
  4. Noisy upon closing

If you have these problems chances are your upper door pin bushings and maybe the door pin itself are worn. It seems that the upper is usually the only problem, the bottom holds up MUCH better. If you are feeling very brave you can do the bottom as well. Be warned, once the bottom comes off realigning the door becomes much more difficult.

The purpose of this article is to fix this problem RIGHT. Many articles mention adjusting things to lift the door back up. This is just a band aid as the upper pin will continue to wear and get worse.

Parts/Tools Needed
Parts needed for each door:
  • Upper Door Pin
  • Door pin bushing (large)
  • Door pin bushing (small)

Tools needed:

  • Large C clamp (a 6" is recommended)
  • Grease or other lube
  • Metal file
  • Hammer
  • Ratchet with 7/16" socket
  • 716" wrench (may not be necessary but good back up)
  • Car jack
  • Punch (you can use your new pin for this, it works fine)
Procedure
  1. Open the door fully
  2. Place jack under center of door and bring up until it just supports door. Do not raise door any higher than it sits.
  3. Using ratchet unbolt all 6 bolts attaching upper hinges assembly.
  4. Loosen but DO NOT REMOVE the 3 hinge to door bolts on lower hinge. Loosen them and much as possible but leave them in one of two turns from coming off.
  5. Pull door back away from hinge to take up slack in lower bolts, be careful door does not fall off jack.
  6. Now there should be enough room to pull out the upper hinge assembly. Try leaning the door forward against fender GENTLY.
  7. You should see the pin in question. Likely there will be a gap in the holes it sits in because the bushings are cracked or even gone, and in extreme cases the pin itself may be worn down.
  8. Use metal file to file off the top of the pin where it has tabs holding it in.
  9. Use C clamp to compress spring slightly to take tension off of pin
  10. Use hammer and a punch or new pin to push the pin out
  11. Pull assembly apart
  12. Replace bushings. By the size of the hole you should be able to tell which goes which. Make sure the "lip" of the bushing faces to the outside of the inner hinge bracket you are mounting them in. This lip acts to hold the
    bushing in and as a spacer to the outer bracket.
  13. With spring still compressed, reassemble assembly. Use grease or lube on pin and inside of bushings. I installed the pin from top down. If you have some way to create that retaining lip you filed off, go ahead and try. By installing top down it holds together fine and won't fall out.
  14. Reinstall assembly in car, attach to body not door first. Make sure it is right where it came off, the body will be marked and you CAN tell.
  15. Use jack to help you get upper hinge to door bolts in.
  16. Tighten everything down.
  17. You may have to loosen the upper and lower hinge to body bolts after test closing to make spacing right. Just loosen them real good then yank the door towards you or away from you to adjust spacing, then retighten.
  18. Your door feels like its new!


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