Door Hinge Pin and Bushing Replacement
Worn hinge pins cause doors to sag and require lifting to latch. Hinge bushing kits available; the upper hinge is harder than the lower because the fender corner blocks access.
XJ doors sag because the door hinge pin wears a groove in the brass bushing. Symptoms: door drops as it opens, requires lifting to align with the striker, popping noise. A door hinge bushing kit (Dorman 38389 for upper, 38390 for lower) costs about $15 per door and is a DIY job. Pop out the old roll pin from the bottom (drift it down with a small punch and hammer), remove the worn brass bushing, press in the new one, drop in the new pin. The upper hinge of the front doors is partially blocked by the fender corner - you can either work it in place or remove the fender for clearance. Lubricate the new pin with Lithium grease. Replace the door check arm (the strap that holds the door open in positions) if it is rusty - they snap and the door swings into the fender.
Why it works
- Fixes door alignment cheaply
Trade-offs
- Upper hinge requires fender removal for accessible
Tools required
- pin punch
- hammer
- pliers
- grease
Parts
| Part | Vendor | Est. price |
|---|---|---|
| Hinge pin/bushing upper | Dorman | ~$15 |
| Hinge pin/bushing lower | Dorman | ~$15 |
Sources
Related
Written and maintained by an AZ wheeler and driveway wrencher. How we source guides. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.