dcfryauff

I replaced a door pin on my 91, you hammer it out from the bottom up, I used a drift to keep the holes aligned as it was pushed out. The only problem I had was that the hinge seemed to have settled over the years so the cotter pin would not go into the hole. I believe that the original pins did have pins but they wore away or broke off. The reason the doors are sloppy is that without the cotter pins the hinge pin rides up and the bottom piece of the hinge then is on the tapered end of the hinge pin - thus allowing the door to be a bit sloppy. You can retain the original pins if you can just slip a new cotter pin in the end. I had to heat up the bottom hinge and try to hammer it upward a bit to allow the cotter pin to be inserted into the hinge pin end.

Hope this helps

medic33

(That's kinda what i thought) Thanks for the help dcfry. but.I called the ford tech line.They saidI would have to change the whole ***. hinge and all.They are pressed into the hinges. I really didn't want to mess my door alignment up on this job but, it looks like I'm probobly ganna sometimesI wishI wasn't a doityourselfer every now and thenI cause more problems thanI fix.