Pin and Bushing kit replacement instructions

Before you begin your 3rdgensolutiond pin installation read through all these instructional steps and familiarize yourself with our installation process.
  Open the door. Roll the window all the way down. The weight of the door must now be supported while the hinge pins are being removed. A good idea is to use an engine hoist, as this can support the door without getting in the way. I wrap a nylon strap around the door at the center of gravity so that it chocks the door. Then attach this to the engine hoist. Use only enough pressure to take the weight of the door off the hinges. If at all possible try to avoid friends holding the door up or trying to balance it on a bucket, as this can quickly lead to problems!

Some users have reported that access to the upper hinge can be greatly improved by removing the upper door trim panel and remove the door weather strip by unscrewing the two retaining screws.

  Apply duct tape or some other suitable protective layer to the rear most portion of the fender top to bottom. Then apply the same material to the front of the door at the upper and lower 6"or so. This is done to prevent accidental damage to the paint on the door or fender while the hinge pins are removed. One small slip can result in chipped paint. Be careful.
  Using a large pry bar, remove the lower door hinge detent spring. To prevent the spring from flying loose when removing it, cover the spring with a shop towel or old rag. Set the spring aside, as it will be reused.
  Move the spring retainer on the lower hinge pin out of it's position, and remove the lower hinge pin.

Using a Dremel tool with a small grinding disc, or similar, grind off the swaged ends of the of the upper hinge pins. (Top side of the upper pin and bottom side of the lower pin)


There is an alternate method of doing this which is used by some body shops. It involves drilling the head off as you would with any rivet. This method is best left to professionals, as one small slip can result in damaged paint or worse. The process is illustated below



While maintaining a steady grip on the door, tap out the old hinge pins.


move the door slightly away from it's normal position and tap out the old bushings.


Use the supplied piece of abrasive and carefully clean any corrosion from the bores where the old upper hinge pin bushings were. This step is very important because the new bushings must not be forced into their bores whatsoever. They are designed to be a slip fit. The clearance between our replacement pins and bushings is designed to be only one thousandth of an inch(.001"). So any forcing of the bushings into their bores will result in the bushings closing up, which in an extreme case will prevent the new pins from passing through the bushings.

Before proceeding to the next step it is wise to check that the new hinge pins will still fit into the new bushings, and are a good 'sliding fit'.

Open the package of Loctite 271, which is supplied in your kit. Apply 4 or 5 drops of this special adhesive to the smaller outer diameter of the bushings where they meet the bushings flange. Immediately insert the bushings into their bores, rotating them slightly to spread the adhesive evenly. Allow the adhesive time to set, approximately 20-30 minutes.


  As the bushings are a "slip fit ", the lower bushing must be held in place as the adhesive sets. This is easily accomplished with light finger pressure or a rubber band stretched between two large paper clips.
  If desired now is the time to replace your lower hinge pin bushings.
  Once the adhesive has completely set, move the door back into its original position and install the new pins. Installation is as follows:
  1. Move the door back into position. Align the door holes with the hinge holes as best as you can by eye and install the top pin, threads down, through the holes and press it down until it feels solid. You can give it a gentle tap to make sure it is fully home.

  2. NOTE: The pin will not fully seat on the bushing yet as a section of the pin is tapered, and will need to be drawn into the hinge. This happens when the nut is tightened.

  3. Install the special nuts on the pin, but do not tighten fully at this stage

  4. Install the lower hinge pin, from the bottom of the hinge up and install the nut (*)

  5. Now fully tighten the special nuts to their final torque.


  Reinstall the lower hinge detent spring using the special spring compressor (MAC Tools Number DST2190 or similar device)
  Before closing the door, check for fit at the door striker pin and any body interference.
You're done. The original factory door fit has now been restored.