Well unfortunately I have the classic "saggy doors" on my third gen. Now instead of just sagging, while i go down the road the front of the door moves in and out making one horrific racket.

As we all know this is caused by the hinges wearing out, more specifically the bushings in between hinge and pin. Now replacement pins and bushings are available at any Advanced, Autozone, Carquest... but every single one of them tells me that that same pin will work for the top. Now I'm no master mechanic or anything, but the top hinge has two separate hinge pins/ bushings that do not appear removable.

My trusty Haynes manual informed me to grease them (wow thats a lot of help) and all parts stores keep trying to convince me i need their hinge pin for the top but I think they are not smart. Also, I have an '85, '91, and '92 that all have this same problem and the same style upper door hinges, and I'm sure many other people have this problem also.

I'm turning to you faithful 3rd gen.org tech people, please help me find a way to repair or replace that damn upper hinge

 

Top-DownSolutions.com

I've read nothing but good reviews on their kits. Each kit is for one door. The link above is the nongreasable hinges, but they also sell greaseable ones.

I just ordered me up two greasable kits 2 weeks ago. Havn't installed them yet but i'm sure they will be great to have.

 

I'd love to make this improvement with the TDS parts, too...but it sounds like a pretty big project. Keep us posted.

 

I just did mine, both sides, and just the idea of rolling down the roads with no more noises is worth every penny!

 

I would recommond TDS too havent used the TDS hinge kit, but I did use their hatch rebuild kit, and they are awesome probaly the best company I have ever dealed with, nothing but great products..hooray for TDS

 

I installed the greaseable hinge repair kits on my IROC. Ordered the parts from Lon at Top-Down. First side took about three hours, second took about two. Having a helper with the door or an engine hoist is a must if you dont have a door dolly.

 

one problem if it is real bad you may have to replace the hinge. Also bad bushings wher out the hinge that is welded to the door.I drilled out the hinge and used bushings in there too. you can weld the holes,grind flat redrill.

 

"'Now I'm no master mechanic or anything, but the top hinge has two separate hinge pins/ bushings that do not appear removable.""

From what I've read you have to use a Drummel tool and cut the heads off of the pins and replace them with the ones from the kit the other posters are talking about.

 

AndyZ28's version (and it may be the one Lon sells) appeared in Chevy High Performance several months back. Check his site:

http://www.andyz28.com/catalog.htm

JamesC

 

Maybe Lon will jump in here at some point.. the hinge repair kit comes with instructions that guide you through the processes, step by step. Yes, there is a certain amount of grinding off of the top of the OE pins that MUST be done to seperate the hinges. Use a dremel grinding tool or a carbide tip cutter your choice. It's gotta be done. Once flush with the hinge plate, use a punch and bang the pin out.

I found that once the door was off that it was necessary to ever so slightly enlarge the hinge holes so that the brass collar could slip in. Test fit as you go, until the collar goes in without being forced. Again, its shown in the instructions also.

Not a hard or big project at all! Just ask a buddy to help you or have a engine hoist for the door. Just take your time. Those kits are $$ but well worth it.