Upper Driver's door hinge.

[wettone]

I have a 2004 explorer XLT and the upper driver's side hinge is worn to the point theat the door drops a bit when opened. Unfortunately with the info I've gotten, there are currently no factory/aftermarket pin and bushing kits for this model. I have obtained a replacement from ford, and was just curious as to the [potential pitfalls when replacing same.
Any insight, or direction to a tutorial would be much appreciated.
Thanks in advance.

 

[LoKo498]

Hey, I have the same problem.
I haven't seen a how to on this forum for our model (2002-2005).
I went to Pep Boys & saw the "HELP" kits but saw nothing for the Explorer.
What did u purchase from Ford?
Ill stop down there tomorrow & see what they have.

 

[wettone]

Hinge

Our local Ford dealer was more than hapopy to order and sell me a new hinge assembly.
I have searched long to find a tutorial regarding how to change this with no luck.
If someone could help, I'd appreciate it!

 

[Donystoy]

On our last car I had a similar issue and I just loosened up the lower hinge bolts slightly and just tapped it back a bit. Took up the slack in the hinge pin enough to make the door shut perfect. You have to check the gaps around the door to determine if you do this to the lower hinge or tap the top hinge forward. I think I had to remove the inner fender liner on the car to do this. All hinges are usually on a sliding plate inside of the jamb to allow this adjustment. Certainly the proper way is to replace the hinges or install a pin kit (not sure if one is available for the Explorer) to correct the looseness but this fix works in a pinch.

 

[LoKo498]

Id rather install the pin kit if there's one avail. That's what I'm really looking for tho.
I can loosen the hinge & move it a pinch but then it will offset the door alignment on the door jamb side.
I don't really wanna change the whole door hinge assembly, its gon cost too much & just a PITA to change.
thx guys for the advice tho!

 

[LoKo498]

Can someone find out the diameter of the door hinge pin & the length & also the measurement of the bushing.
We can probably cross reference it to another "HELP" hinge pin & bushing kit for the 2002 model Explorer.

 

[LoKo498]

Well since I last posted, I did purchase a HELP part from PepBoys, item #38438
The pin is the same size as the stock pin, whats in there now.
I haven't attempted to change this over yet but I will follow up hopefully next week.
Maybe there is someone who has did this with my model Explorer which is the 2002 4DR XLT.

 

[LoKo498]

Hey, I just wanted to give an update on this door hinge situation.
I have a 02 explorer XLT.
For this generation, there is NO REPAIR PIN KIT AVAILABLE!
I purchased the piece I thought would fit, it was the same length but the bushings are what's important & what was included in that kit was too big. I wish I woulda known this before I cut the old pin out.
I finally went to a junkyard & told them what I needed. I needed the entire hinge.
It really wasn't that hard to change out the old door hinge assembly with a new one.
If I have to do it again, I think I will remove the front fender to get at the front bolt easier.
I did use a swivel extension but was still a tight fit.
I will do a writeup on this during the week & try to get some pics to post as well.

 

[Jason02XLT]

Newbie here but i just thought I'd share my situation
I had the same problem finding door pins I only needed 1 the top drivers side. I ordered a set online only to find out the bushings were too big (after i had already cut my original in half to get it out of course) so i went to autozone to try to match up a set its a "dorman help" number 38403 its a set of 3 two large pins and 1 smaller one the kit is a little pricey at $20 but the small pin and bushings worked great everything fit perfectly and the door opens and closes as it should hopefully i can help someone else out if you need to do both hinges you'll need to buy 2 the small pin is the only one that works
As far as i can tell going by the back of the box the pin is 0.340"×2.8" the bushings are 0.342" ID x 0.511" OD x 0.271" H
Hope this helps