Worn out door hinges

[OR VietVet]

I would need the bushing installer though.

 

[Matthew Jeschke]

I bought the kits from total automotive. They just came today. I need to paint them up and get them on the truck.

 

[OR VietVet]

Pics please. What oversize bushings did you buy?

 

[Matthew Jeschke]

I bought 0.010" over. Upon initial inspection it is clear these pins and hinges are FAR better quality than anything I have seen before.

 

[OR VietVet]

So, to be clear, You bought the 0.010" over bushings. What was that extra cost? Is the larger oversize bushings more expensive than the ones you bought? In the supplied pics, yours look almost more wallowed out that that. Plus, the oversized bushing is round. Is the wallowed out holes on yours round or oblong? Did you get the special tool and the special bushing press?

 

[Matthew Jeschke]

So, to be clear, You bought the 0.010" over bushings. What was that extra cost?

It was $10 / hinge, so $20 total for the driver side door 0.010" hinges. You'll need to change the year for the truck you work on... But this is the catalog with pricing for my 2001:

Hingekit Search For 2001 CHEVROLET Tahoe - 4 Door | Total Automotive

Is the larger oversize bushings more expensive than the ones you bought?

The hinge kit comes with factory spec (dimension) bushings included. The oversized ones for worn out hinges are extra (per above).

In the supplied pics, yours look almost more wallowed out that that. Plus, the oversized bushing is round. Is the wallowed out holes on yours round or oblong? Did you get the special tool and the special bushing press?

It's possible the hole is worn larger than 0.010" I should have taken measurements when I had it apart but silly me I did not. hopefully the 0.010" are big enough.

 

[OR VietVet]

It was $10 / hinge, so $20 total for the driver side door 0.010" hinges. You'll need to change the year for the truck you work on... But this is the catalog with pricing for my 2001:

Hingekit Search For 2001 CHEVROLET Tahoe - 4 Door | Total Automotive

The hinge kit comes with factory spec (dimension) bushings included. The oversized ones for worn out hinges are extra (per above).


It's possible the hole is worn larger than 0.010" I should have taken measurements when I had it apart but silly me I did not. hopefully the 0.010" are big enough.

Were the holes enlarged completely round or oblonged/egg shaped?

 

[OR VietVet]

Only IMO, these kits are great "as long as", the hole is worn bigger "completely round". Also, the hole needs to be worn to the point to accept either 0.010 or 0.020...etc.
If is worn less than the oversize bushing, then the hole has to be drilled out to accept the correct size oversize and completely round bushing.

Again, IMO. Unless I am missing something.

 

[OR VietVet]

I am wondering if the oversize bushings come with instructions telling you to make sure hole is round and what to drill it out to, so the bushing fits correctly.

 

[Matthew Jeschke]

The kit comes with OE spec bushings.

If you buy oversize (an addon) you can sand them down... but they are designed to fit in the hole and excess will peal off as you press it in (to a certain extent). The OD is ridged for this reason to accommodate some degree of out of round and up to 0.010" slack in the hole.

Honestly, I'd just call and ask them questions they were VERY helpful.

 

[YukonGTmaster]

I always throw bearings and bushing that I need to press in, into the freezer for a while. You would be surprised how much they shrink down, and just drop into the boss.

 

[Matthew Jeschke]

Is a GREAT tip. I did that with the stator when building my transmission pump. I'd not even thought to do that here! Thanks!

 

[Matthew Jeschke]

Unfortunately, my hinges are REALLY badly worn. I did the repair today and even the oversized bushings slid into the holes really easily. I also suspect the holes are out of round as one would expect with this kind of wear.

Good news is, the door is on, ZERO wiggle in the hinges, and for the first time since owning the truck it aligns PERFECTLY with the rest of the body... No more droopy door! It's worth noting none of the other attempts to rebuild the door and numerous other kits got me even close to this good of results.

I saved more notes on my website: https://matthewjeschke.com/gmt800hingefix/

 

[OR VietVet]

Unfortunately, my hinges are REALLY badly worn. I did the repair today and even the oversized bushings slid into the holes really easily. I also suspect the holes are out of round as one would expect with this kind of wear.

Good news is, the door is on, ZERO wiggle in the hinges, and for the first time since owning the truck it aligns PERFECTLY with the rest of the body... No more droopy door! It's worth noting none of the other attempts to rebuild the door and numerous other kits got me even close to this good of results.

I saved more notes on my website: https://matthewjeschke.com/gmt800hingefix/

You said you ordered 0.010 bushings. Sounds like you need to step up and do it again with 0.020 bushings.

 

[Matthew Jeschke]

Possibly, not even sure if they made those. I didn't see anything larger than a 0.010" on their website.

Correction, they do offer 0.020" and 0.030" oversized bushings! Thank God!

 

[OR VietVet]

Oversized bushings available for severely worn or previously repaired hinges. Part #: GMB003A (.10 oversized) & GMB003B (.20 oversized). We no-longer offer painted kits!

Possibly, not even sure if they made those. I didn't see anything larger than a 0.010" on their website.

This statement is in red on the pic and ad text that comes up with the link. Did you freeze them and put them in or the holes were wallowed out, that you did not have to freeze them? Were both holes wallowed out the same amount?

Asking so many questions because of the ones I did on a friend's 2005 Tahoe about 7-8 months ago. hers were sloppy but not as sloppy as your video. I think the 0.010 will work in hers. At least I know what I am up against, taking the door off again.

 

[Matthew Jeschke]

Oversized bushings available for severely worn or previously repaired hinges. Part #: GMB003A (.10 oversized) & GMB003B (.20 oversized). We no-longer offer painted kits! This statement is in red on the pic and ad text that comes up with the link.

That's great news, as next time I'll probably try some 0.020" over bushings.

I stand corrected, total automotive does have larger bushings. They do 0.020" and 0.030".

Thanks!

Did you freeze them and put them in or the holes were wallowed out, that you did not have to freeze them? Were both holes wallowed out the same amount?

I did not freeze the bushings. They just pressed in, mostly by finger force. When I put the pins in and tightened them they went in the rest of the way. That said none of them could wiggle when in the holes. I'm not sure what a good hinge rebuild would look like though... I'd image it'd be a tight fit but not quite interference fit?

Hard to say how out of round the holes were. I should have took a few measurements but only took one. The ridged OD worked beautifully. I noticed it conforming to the shape of the hole (I put one bushing in slightly and pulled it back out).

Holes were all a bit different. Here's my measurements...

Asking so many questions because of the ones I did on a friend's 2005 Tahoe about 7-8 months ago. hers were sloppy but not as sloppy as your video. I think the 0.010 will work in hers. At least I know what I am up against, taking the door off again.

I'm totally sold on this kit. I cannot believe how straight my door is now. In hindsight I should have measured the holes in the hinge each time I took the door apart. Would have been great information to have.

You can see in my notes above that one of the holes was of 0.003" larger than the oversized bushing. In hindsight I'd have probably ordered a couple kits of 0.010" another of 0.020" over so I had at least one 0.020" bushing to try on that larger hole. With time I'll be able to tell if 0.003" is too much slack in the hinge knuckle.

Darn this door, I had to walk out like 10 times last night and pinch myself to realize the door actually lines up, opens and closes correctly. I even went and looked at it again this morning before breakfast lol

 

[OR VietVet]

I say, give it time. The weight of the door and the open and closing process will determine what happens next. Because the holes are likely wallowed a bit oblong/egg shaped, the bushings will reshape a bit and the difference will show at the end of the door where the seam is when closed. I do hope that it goes better than that for you.

The video of the play before the over sized bushings, had me thinking that you would need, at a minimum, the 0.020 bushings. I would be interested in seeing a video of any perceived play, at this time.

 

[Matthew Jeschke]

I could make a clip when I get a chance. Although I feel zero slop in the door. It no longer wiggles at all.

 

[OR VietVet]

I could make a clip when I get a chance. Although I feel zero slop in the door. It no longer wiggles at all.

If there is "0" play and the alignment is good, then it is a win. Does the latch close smoothly?