Originally Posted by tssguy123

These are (I believe.. they are on 97+) t40 bolts. They're a pain in the *** to remove (hard to get a ratchet and bit in there) but it can be done. I used a box end wrench with the t40 bit.

You wouldn't want to do this process more than once. The doors are heavy, the bolts have a **** ton of thread, and it's a pain in the *** to align properly.

Originally Posted by holycaveman

I have a 2000 model.

Only parts you will need is two hinge pin sets from autozone or similar.

Its important to use the provided bushings. My door was sagging already. This mod tightened things up like new.


The weight of your door is carried on the lower hinge. So only the top hinge ear is really needed on the lower hinge. However I left both ears on the lower hinge that is mounted to the jeep to save time. I drilled these two holes out so the bushings had to be pressed in. Welded the new pin to the door side lower hinge top ear. Bottom ear has to be removed.

For the top hinge no ears are removed! The top hinge supports the door. So it has more side loads. Simply drill out the body side hinge holes so the new bushings have to be presses in. Drill the door side upper hinge exactly to the size of the pin. To do it even better you would install new bushings on the door side upper hinge also.

The upper pin installs from the bottom with a clip.

Your door is heavy. So doing it this way let's you simply set the bottom pin in the hole first. Then you slide the upper pin in by hand. Much easier than holding the door and trying to align both pins at once.

And you get a no slop door.

On the upper pin you can use a clip to hold it in place or a pin if you drill a hole for it.