Hi:

How can you remover the door to replace the bushing and the roller on a 1991 Camaro? Do you have to remove the hinge from the body? Does fenders need to come off to unbolt the hinges? Or, the door can be taken off just by removing the spring and the pin?
Thanks

 

The short answer is yes, you can remove the door without removing the fender. Just follow the instructions below.
Removal

1. On doors that are equipped with power operated components, do the following:
   1. Remove the door trim panel and inner panel water deflector.
      
   2. Disconnect the wire harness from all components in the door.
      
   3. Remove the rubber conduit from the door, then remove the wire harness from the door through the conduit access hole.
      
2. Tape the area (on the door pillar and body pillar) above the lower hinge with cloth backed body tape.
3. Insert a long, flat-blade screwdriver under the pivot point of the hold-open link and over the top of the spring. The screwdriver should be positioned so as not to apply pressure to the hold-open link. Cover the spring with a shop cloth or rag and lift the screwdriver to disengage the spring. The spring can also be removed by using tool J-36604 (or equivalent) door hinge spring compressor tool.
4. With the aid of a helper to support the door, remove the lower hinge pin using a soft-headed hammer and locking type pliers. The helper can aid the hinge pin removal by raising and lowering the rear of the door.
5. Insert a bolt into the hole of the lower hinge to maintain the door attachment during upper hinge removal.
6. Using a 13mm socket, remove the upper hinge bolts from the pillar. Remove the bolt from the lower hinge and remove the door from the body.
   

To install:

1. Replace the hinge pin clip.
   
2. With the aid of a helper, position the door and insert the bolt in the hole of the lower hinge.
   
3. Bolt the upper hinge to the body. The lower hinge pin is installed with the pointed end down.
   
4. Remove the screw from the lower hinge and install the lower hinge pin. The use of tool J-36604 or equivalent is recommended for installing the hinge spring.
   

If the spring is installed before installing the lower hinge pin, damage to the hinge bushings may result.

1. If the spring was removed using a screwdriver, install the spring as follows:
   1. Place the spring in tool J-36604 or equivalent.
      
   2. Place the tool and spring in a bench vise.
      
   3. Compress the tool in the vise and install the bolt until the spring is fully compressed.
      
   4. Remove the tool (with the compressed spring) from the vise and install in the proper position in the door lower hinge. A slot in one jaw fits over the hold-open link. The hole on the other jaw fits over the bubble.
      
   5. Remove the bolt from the tool to install the spring.
      
   6. Remove the tool from the door hinge (tool will fall out in three pieces). Cycle the door to check the spring operation.
      
2. Remove the tape from the door and the body pillars.
   
3. On doors with power operated components:
   1. Install the wire harness to the door through the conduit access hole, then install the rubber conduit to the door.
      
   2. Connect wire harness to all components in the door.
      
   3. Install the inner panel water deflector and door trim panel.

 

Thank you very much for detailed instruction.
Much appreciated.

 

As above, don't attempt to do this by yourself unless you can borrow a door dolly.

GL with the repair.

 

So, I've done this a few times, and I found that a little hard to follow. Not saying Spurgeon76 is wrong, just not intuitive based on how I've done it. Once the wiring is out of the way, removing the whole door isn't very difficult. Frankly I think reaching inside the door frame to remove the wiring is the most PITA part of it. ...that being said, I can understand wanting to leave the door on, but trust me, it's SO much easier to just take it off.

To address the door/fender: If you remove the wheel, and a few of the plastic rivets holding the fender liner on, you can reach any remaining hinge bolts from the wheel well. I think I only needed to do that for 1 bolt. Once those bolts are out, you now have the door, free of the car, the hinges are still completely intact and assembled, both sides attached to the door.

The top hinge: I used a cut-off wheel to cut off the old pins. It's not hard, you just have to be careful not to go crazy with it. Just take your time, moving the hinge around a little for the best angle. First time I did it, it probably took me about an hour of messing with different tools and punches, cutters, etc. etc. Second door I just used the cut off wheel and it took about 10 minutes. Once the upper pins are out, my bushings just fell out, but a punch may be necessary. Clean it up and reinstall the new pins and bushings.

Spring on the bottom hinge: The tool is less than 10 bucks. It's worth buying. It's under a LOT of pressure, and even if you safely remove it, I don't see how you reinstall it without the tool. I'm sure it can be done, but for under 10 bucks....buy the tool.

Lower Hinge removal. Once the spring is off, a punch should easily pop the old pin out. One of mine was pretty nasty, and it still removed easily with a few good wacks of a hammer and punch. Then just punch out the old bushings. Very easy.

Roller Pin: Here's the part where you have to make a choice. The roller and pin don't come in the rebuild kit. And after purchasing it separately, from the reading I've done, removing it from the hinge and reinstalling it is a huge pain in the rear. I purchased the entire body side half of the lower hinge, which comes with the roller already installed, ready to go. I just tossed the old body side hinge and installed the new.

Here's a thread where we were discussing some of this, with pics and part numbers.
https://www.thirdgen.org/forums/body...d-replace.html

 

Thanks again for all the useful pointers.
My only concern about removing the hinges would future misalignment of the door.

 

There's not really any adjust-ability. I've done this 4 times now and never put any effort whatsoever into trying to align the doors and they've always gone back on perfect.