I got an 1984 Cherokee 2 door and the upper hinge is broken off at the post. I'm building the courage to tear into it and see how extensive the damage is. I'd like to know if anyone has seen this or can give a 'heads up' on what I should look for when I get into it. Any help would be helpful as I am a G.M. man at heart. ( Please don't judge me) Thanks, Billy

 

This is common, espescially on the heavier two doors. Weld it back where it originally sat.

 

I can give some insight...

First, you will need a good welder.
Second, you will have to remove the fender. (Header panel also, but that is easy)


After fender has been removed, unbolt hinge from door.
Sometimes, especially with a heavier 2dr...door removal is in order.

Taker the now free hinge and wire wheel all around where you are going to weld.

DO NOT, I repeat DO NOT remove and left-over metal from the pillar.
WHY?
It will act like a puzzle piece and allow you to position the hinge EXACTLY where it needs to be.

ALSO: You will need to remove EVERYTHING around the weld area.
Jeep laid a thick layer of sealant around the weld.
If you do not remove it down to bare metal...
You will become an expert at this repair as you will be doing it AGAIN after the weld fails.

NOTE: Place a piece of plywood or cardboard alongside your dash and down to the floor. This will keep you from making your interior crispy. Unless you like the "Burned Car" air fresheners

Give the hinge a good bead all the way around.
Then, do it again but out just a tad from your first.
The pillar has two layers of metal EXCEPT right where the hinge is welded on.
GO ENGINEERS!!! (NOT)
If you can make your second pass around reach this second layer..you're golden.

Clean up the entire area and give it a coat of primer, then a coat of your favorite color paint. I recommend body color as it will help hide the repair.

Hang the door.
There are holes in the hinge to allow you to tighten the bolts while the door is closed. This will let you align the door perfectly...then tighten the daylights out of it.

Make sure the door is aligned properly before reinstalling the fender and header panel.
Nothing worse than having to remove all that again to fix a mis-aligned door.

Also...don't forget to install the door keeper pin, this will aid in keeping the hinge from being stressed the wrong way and failing.

 

I thought changing hinges on my Dodge Ram truck was bad until I read your Jeep repair. Compared to this, mine was a piece of cake. They bolted on but a bolt on each of the cab side threaded from the inside. The bottom hinge was easy but the top hinge was a real pain. I love these engineers. The Jeep Grand Cherokee AC drain is another marvel of engineering.

 

I did this repair on our 91 Laredo when we first got it.

I was surprised at how easily the header assembly and fender came off.
Our 91 is a 4dr so it wasn't as heavy as the 2dr.

Took roughly 2hrs for the repair.
And thats not being familiar with the XJ construction as I am now.

Now probably would take 1 1/2hrs

 

read this ......http://www.go.jeep-xj.info/HowtoDoorHinge.htm

and this for the factory TSB and upgrade hinge ........http://www.i-car.com/html_pages/tech.../070102b.shtml

and another......http://www.naxja.org/forum/showthrea...welding+hinges