Replacing hinge pins and bushings 2004 Ram 2500
 

Has anyone done this?
I bought the Doorman 38479 kit listed below.
I was planning on using a sawzall to cut the old hinges with the door blocked up, and to do them one at a time.
Any thoughts?

38479
Door Hinge Pin And Bushing Kit
Application Summary: Dodge 2010-02

Application Notes:
Front

Application Attributes:
Package Contents: 3 pins (2) 0.373" x 3.250" and (1) 0.255" x 0.374" x 2.775", and (4) bushings (ID x OD x Height) 0.448" x 0.553" x 0.748" and (3) E-clips (2) 3/8" and (1) 1/4"


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I'd unbolt each side instead of using the sawzall.

SJ03

So basically your saying take the door completely off, then take the hinges off the truck side, then replace pins/bushings? I will still have to cut the factory pins as they are not secured with an e-clip... They look pressed with a rivet type design.

That's what I'd do. Also, use a hammer drill with a pitchfork type end and it'll cut them right off.

Why would you change those out though? Try some white lithium grease first. Swing the door open and close lots of times. Not all the way, just enough to work the grease in. Then add a little more and be done.

SJ03

Because my door sags when I open it and then it doesn't seal right. I get a lot of wind noise when driving... I was under the impression that my bushings are probably worn out so I bought the kit. Thoughts???

Ah, I see. Yup, that would warrant the new kit. :)

With the door open, does it move up and down with you lift or pull on it?

How are your door seals by the side view mirror, that goes around the cab? I know there was a TSB on mine when I bought it. The corner of the door, by the side view mirror, was hitting the seal and cut a big hole in it.

SJ03

Let me see if I can get it to move up or down when open.
Yep, I have the big hole in the seal.
I thought that was caused from the door sag.
What was the TSB fix for the issue? Do you know how I can look it up?

I had to buy mine from the dealer. About $110 or so for both sides. It was a poor design. TSB 23-049-05.

I'd replace those first before messing with kit. Don't forget the white lithium grease. Both sides.

SJ03

Ok, thanks for the info!
I will go that route first.

Post back after test drives. :)

SJ03