ALL Corvette Tips and Tricks - Body - Door Hinge Pins

well this job can be a bugger at times. The top pins can give you problems because of the clearance problems from the front fender. That usually requires loosening the hinges to gain the necessary room for removal and installation. If the pins are all loose the job goes much easier. If you have a floor jack it can be used to support the door while you work. Be sure to use padding of some sort to avoid paint and door damage. If the pins are so tight that you can not remove them using a suitable hammer and punch, you are going to have to remove the door. This is a pia. be sure to scribe carefully around the hinges to get the close to their original position. Note the doors often must be readjusted after new pins and bushings are installed. The bushings are very brittle and break easily so be careful when installing them.
Now for a trick or two!!! If the top pins are really loose you can get them out without body damage! Place support under the door to support it... preferably a jack and remove the top pin first. You will notice the clearance prob I mentioned. But they some times come out due to sloppiness. If you are successful carefully lower the door until you get enough clearancs to install the bushings. Not too far!! You can now grind away a small portion of the pin head so it will just clear the fender when you attempt to install it. Face the ground portion away from you when you install the pin and the ground portion will be hidden from view. Getting to the hinges to remove the door is a royal pia... more so if you have elec windows etc etc