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Ford Mustang V6 1994-2004: How to Replace Door Hinges

Replacing the door hinges on your Mustang is not as easy as you'd hope it to be. However, we created this guide to help guide you through the hardship.

By Neftali Medina - September 24, 2015
Contributors: Pet Rock Garage, lastmoto777

This article applies to the Ford Mustang V6 (1994-2004).

Are your doors starting to sag? Although this is a problem that rarely occurs, sagging hinges can result in you having to induce leverage in order to close your door. I've had personal experience with this matter, and it does have its eventual wear on your soul. Unfortunately, door hinges are not the most user-friendly repair, and require the fender and dash board to be removed. The amount of work required to replace them often have people turning away from the repair and just dealing with the sagging doors. However, if you have a day to spare use these instructions as a guide to replace the hinges on your Ford Mustang.

Materials Needed

  • Phillips screwdriver
  • Jack
  • Jack stands
  • 8mm socket
  • Ratchet
  • Several extensions
  • Screwdriver
  • Hinge rebuild kit
  • 15/32" bit
  • Punch
  • Hammer
  • Pliers

The following steps focus on replacing the lower hinge. However, due to the amount of work required for the top hinge, the last steps instruct how to rebuild it instead of replacing it.

Step 1 – Remove the front fender

You have to remove the front headlight and fender in order to gain access to the hinge bolts.

  • Remove the clips holding the headlight in place.
  • Disconnect the bulb plugs.
  • Remove the headlight housing.
Figure 1. Remove the bulb housing.

There are several 8mm bolts, clips and Phillips screws holding the fender in place. Use Figure 2 as a point of reference. The two holes on the bottom right side are also 8mm bolts, so you'll have to remove the trim piece in order to gain access.

Figure 2. Location of all the mounting bolts on the fender.

To gain access to some of the bolts under the fender, you will have to remove the splash guard.

  • Take a jack and raise the chassis, then support it on jack stands.
  • Remove the 11mm bolts holding the splash guard in place.
  • Then remove the rest of the fender bolts.
Figure 3. Remove the wheel to gain access to the splash guard.

Step 2 – Remove the 13mm hinge bolts

  • Keep the door shut and locked.
  • Loosen the 13mm bolts holding the bottom hinge in place.
  • Remove the hinge.
Figure 4. Remove the 13mm hinge bolts.

Step 3 – Install the new lower hinge

  • While the door is still shut, align the new hinge to the door.
  • Tighten the 13mm mounting bolts.
Figure 5. Install the new lower hinge.

Step 4 – Cut the pin for the top hinge

You can repeat the process for pre-1999 Mustang models. However, models built between 1999 to 2004 is where everyone feels Ford made a mistake. In order to remove the top hinge on 1999 to 2004 Mustangs, you have to remove the entire dashboard. Now, if you wish to do that for a door hinge, by all means do. However, bear in mind that removing the dashboard requires at least one full day to do so. So instead of removing the dashboard, we opted to save some time by showing you how to install new door pins into the hinges.

  • Figure 6. Hinge pin location.
  • Figure 7. Door hinge kit.
  • Grind down the top portion of the stock pin.
  • Slide out the old pin and chisel out the stock bushings.
  • Remove the door portion of the hinge from the door and place it on a flat surface.
  • Use the 15/32" drill bit and widen the holes on the stock hinges.
  • Press in the new bushings.
  • Install the hinge back onto the door.
  • Press in the new door pin.
  • Install the lock ring or cotter pin to lock the door pin in place.
  • Figure 8. Shaved hinge pin.
  • Figure 9. Hinge pin punched out.
  • Figure 10. Old bushings removed.
  • Figure 11. New bushings pressed in.
  • Figure 12. Hinge pin installed.

Align the door back to its location and tighten down the hinges. Reinstall the fender, splash shield, trim pieces and wheel, then lower the car. That's it, you are finished!

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