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excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 6005

1999 Defender 110 Td5 SW Caledonian Blue

Rear door hinge bolt replacement

I had in stock the bolts for the rear door and new door hinge pins. Having a free day and some time....why not.

I started with the top hinge and worked down

Of the top of my head tools used:
Torx bit
10mm spanner
13mm spanner and socket
Impact gun with large cross-head screw driver bit
Centre punch
Hammer
Coffee
Radio
Vice
Cloths
Penetrating spray
Grease (both copper slip and Moly grease)

Removed interior rear trim to get the body side nuts (13mm) and rear door nuts also 13mm
Luckily I had access to a cordless impact gun and some bits that came with a 1/2" impact driver so I made full use of theses tools to remove the bolts.(not been off since the car was made I guess and tighter than a gnats chuff)

You need to remove the hinges if you have play in the hinges
See >

Undo the two bolts on each side of the hinge and remove from the body work
Off the car you are presented with:

Click image to enlarge

In a vice with the jaws covered in a cloth undo the 10mm nut and stop the other end rotating (torx bit)

Click image to enlarge

Once undone, you might have to use a centre punch to remove the pin (one hinge I did needed a good beating with a hammer)

The pin setup consists of;
A centre pin
A brass sphere
A spring (maybe a washer)
10mm nut

One half of the hinge - note the sphere

Click image to enlarge

The other half - note the spring.

Click image to enlarge

Remove these old bits and replace with new.
I took the chance to give the hinges a clean up and remove the old crud and gave them a spray with 3 in 1 oil and another wipe.

Old bits - as you can see the pin is bent and a chunk is missing

Click image to enlarge

Reassemble the hinge (I used copper slip on the moving parts)

Pin into the hinge (as it was before) add the sphere, add the other half of the hinge and add a new spring. Attached the nut and tighten up.

Check for movement i.e not too stiff to move.

Add back to the car, tighten up the bolts.

Middle hinge needed my door card removing and also the lower speaker panel removing if you have one. I found I had captive nuts on a plate on the inside of the car

Bottom one a bit more awkward as the body bolts are behind a panel in the wheel arch.
I tried the trusty impact gun to remove these screws but just trashed the head of the bolt. Ended up drilling ou the bolts and using the centre punch to pop the bolts out.

My door moved a bit during the work and as such I had to slacked off the hinges and adjust accordingly and also adjusted the door striker catch. The door closed much better now.

My bolts got replaced with stainless ones. 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

1st Apr 2018 8:19pm

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