The replacement door Pins and Bushings are usually from Dorman. Slide the Bushing on the Pin, and feel the slop. Seems to me they should fit tighter on the shaft.
I watched several YT`s on how to replace them. OH that`s easy... one guy has a floor jack under the door, and uses a drill to drill off the riveted head off the pin. Then drive it out.
I could not get the drill and bit to line up because of door, windshield post etc... of bit too short...
I finally, removed the 2 bolts top/bottom off the hinge and lifted the door off and sat on ground resting against the fender.
The top hinge has that little white roller thingy that hold the door open. I had new one`s as mine was flat on one side.
new one comes with a new shaft/pin it rides on. Drove it out with a punch, and the new one used my 20 ton HF Hyd press to slowly push it in.
With a punch drive out of the old Bushings, and tap the new one`s in.
Drop in the new Door Pin and drive it in solid.
Under the head of the pin are some splines that are to bite into the steel part of the Hinge. I could not get it in very far, maybe if the Hinge was removed from the body, and using a HYD Press it would go in all the way?
I still have the slop with the door as I lift it up and down. also the Door pin came up and later the Bushing broke. OH Great!!!
O`Really`s sells just the Bushings, 8 come in the package. Only 2 fit the Ford. others are for a Chevy, Dodge and Toyota, and think they are 10 Bucks.
On one thread the guy said just buy new hinges and be done with it....but also said after market ones are not all that great, and to find good tight OEM one`s in the JY and be better off.
Once in a while PNP will have a $25 sale on Hoods, Fenders, Bumpers and Doors. I have some good tight hinges especially the Pass side from all the Doors I have dragged home.
But how do you access the bolts on the body to adjust the door with the new Hinge? remove the fender?
I did have a crazy thought, to but some bolts, maybe grade 8 1/4" or what ever size it is. Have them turned down to a snug fit into the Bushings.
Either thread the lower end for a Ny-Lock Nut or drill for a Cotter Pin.
OK Iam done babbling....
Here it a thread I saved I forgot about till now,
Technical instructions on how to replace/fix your 89-97 Ford Thunderbird or Cougar door hinges. It is common for them to wear and the door to sag.
www.blueovaltech.com
A good YT Vid.
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Vid on door handle fix plate
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Bronco Grave yard has the plates.
Black metal,will also fit 1987-96br E7TZ 1522600-A FORD MOTOR COMPANY
shop.broncograveyard.com
Goat