A sagging door can cause several problems for you, including leaks, metal damage, and paint damage. A Jeep door hinge has two pieces. One is welded to the body of the door and the other rotates on a pin as you open and close your door. Over time these pins can rust or lose their bushings, causing the door to sag. A smooth replacement will take about two to three hours to complete.
Tape off the corners and edges of the door where the replacement is needed. This will protect your paint and prevent the need for more repairs later. Don't use any other type of tape, as it can leave residue that will need to be cleaned later.
Open the Jeep door and locate the electrical connectors that run through the inside door jamb. There is a plastic green clip with two tabs on it. Remove this piece by squeezing the tabs. Once it is removed from the door, you will see the electrical connectors for the door controls.
Use the flathead screwdriver to unlock the clasp that holds the connectors in place. Disconnect the plug by hand.
Support the door on a stand of some kind. You can use a floor jack, wooden stand, or anything that is level with the bottom of the door. Remember that these doors can weigh upwards of 100 pounds.
Use the 9-millimeter socket and ratchet to remove the four door bolts that hold the door to the Jeep. Make sure that the door is supported very well before removing these bolts.
Lay the door on a work table and remove the old hinges, one at a time. Use the cut-off wheel to cut the head off the door pin. This will allow you to remove the pin. With the head off the pin, use a small screwdriver and hammer to tap the pin out of the door hinge. There are two pieces to the hinge. One is welded to the Jeep door and the other moves along the pin. The moving hinge can now be removed with the pin.
Place Lithium grease on the new pin and install any bushings that go with the pin. Install the new hinge and pin through the hinge frame, which is still on the door. Place the moving hinge piece through the hinge frame and line up the holes so that the pin goes through all of them.
Repeat Step 7 on the other hinge. Use the completed hinge as a reference if needed. With both hinges done, the door can be reinstalled and the electrical plugs reattached.
