2nd Gen Non-Engine/Transmission Door Hinge Troubles

[WStrong]

The pins and bushings on my driver's door on my '97 Cummins are all worn out. The dealer sells the whole hinge only for $150/pair#@$%! and the pin and bushing kit I got at Napa were too small. Has any one else had this problem and how did you fix it. Thanks

 

[HCannon]

I fixed mine by getting pins and bushings for a Chevy. They will be too big. You will have to drill out for them to to fit. It worked for me for several years until I sold the pick-up.

 

[rotohead]

rockauto.com has repair kit # 38423 which is two different length,size pins, four bushings and two c-clips. I bought four to fix my truck. Can anyone describe how to do this properly. Does it take a shop press or just a vise. I assume you take off one hinge at a time. What's the best way to prop the door up?
I'm a lamo when it comes to NO INSTRUCTIONS!!! Too much Army training. Anyway, any help would be greatly appreciated w/o starting another thread.
Chuck

 

[GAmes]

I got mine from this guy.



eBay Motors: 1994-2001 94 01 Dodge ram Truck door hinge pins pin (item 200211986864 end time Apr-05-08 17:22:34 PDT)



I lifted the weight off the hinges with an engine hoist. The wires into the door have the connectors inside the rubber boot, disconnect there. Mark the hinge locations on the door and remove the bolts that go into the door, not into the door frame. Once the door is off the hinges are easy to access. Drive the old pins out (make sure to remember how the spring and bar are installed in the top hinge) A little drilling/filing may be needed for the new pins. Drill sizes are on the instructions. Assemble the hinges and remount the door. It took awhile to do the first one, but I could do it in less than an hour per door now.

 

[rotohead]

I got mine from this guy.

eBay Motors: 1994-2001 94 01 Dodge ram Truck door hinge pins pin (item 200211986864 end time Apr-05-08 17:22:34 PDT)

I lifted the weight off the hinges with an engine hoist. The wires into the door have the connectors inside the rubber boot, disconnect there. Mark the hinge locations on the door and remove the bolts that go into the door, not into the door frame. Once the door is off the hinges are easy to access. Drive the old pins out (make sure to remember how the spring and bar are installed in the top hinge) A little drilling/filing may be needed for the new pins. Drill sizes are on the instructions. Assemble the hinges and remount the door. It took awhile to do the first one, but I could do it in less than an hour per door now.

The "kit" I got from rockauto.com isn't anything more than two different size pins, four bushings and two c-clips. No instructions. I'd love to see a copy of the instructions you have but don't want to step on any toes. Even the info in the instructions (drill bit sizes, etc) would be of great help. I thought I read one thread where the guy minimally supported the door and took one hinge off at a time, but I think I like your idea better. Leaving the hinge on the body makes sense to me.
Does anyone know if there are instructions for this somewhere out there?

 

[GAmes]

The instructions are specific for his pins because both the pins and bushings are a little oversize. To tell you the truth, once you have the hinges off and dissassembled you will prolly find that all you need to do is install the replacements you have. If they are oversize a round file will do the job. PM sent.