If you've never done this before, it's a genuine PITA.


First, jack up the rear of the door slightly to take some weight off hinge.



Next, remove the interior trim panel to access the single hinge bolt from the inside of the car.



Now the fun really begins. There is a bolt on the outboard side that is quite difficult to even see, let alone remove it. I used a slimline end wrench to grab it between the door frame and the roller pin.



After this bolt is removed, jack the door up a little more and the entire hinge slides out toward you. Remove the worn bushings with a small drift, install the new bushings. you can now put it all back together in reverse order.

It's important to note that getting that one outside bolt back through the hinge and into the threads requires a great deal of patience. Have a magnet handy... I assure you that you will drop the bolt down in the corner of the fender a half dozen times.

[This message has been edited by rpro (edited 02-06-2009).]

I just did this too. Replaced the lower and upper pins & bushings and installed new rollers. I took the doors completely off the car though. It is not the easiest way but I had to straighten one and I rebuilt the window tracks,motors and installed new door glass and inner & outer dew wipes. Installed new door locks and feux dynamat on the inside of the doors. It was a big job but it is so nice to have doors that work correctly. They were not fun to get aligned but it's done!

I need to do this to my car too......the drivers door is getting pretty bad.

I've never put pins in a Fiero but several S10's, '78 Malibu and a '76 Cadillac. Why did you have to cut a hole thru the kick panel to change only the pin?

I didn't cut a hole. There is tar paper covering the access hole, I just removed the paper, which is what you see in the photograph.

Concrete, WA? I just moved here from Snohomish.

[This message has been edited by rpro (edited 02-06-2009).]

Congratulations on getting that job done, sure is a pita of a project. I just did the same on my 86 Fiero, I took the door right off but I've got use of a HiLo, makes it easier, but not by much. I did a full rebuild and added a nylon washer in the lower hinge like theogre mentioned in his cave.
I couldn't get that stupid spring back in despite Rodneys spring compressor, maybe when it warms up, I'll try again. So how did you get your spring back in place?

Oh, it looked like metal. Did you say you moved to Snohomish or Concrete? Concrete is 45 minutes NE from Mt. Vernon up Hwy 20 after turning off 5 on to Cook Rd. Reread your post, you moved FROM Snohomish to CO.

[This message has been edited by raysr11 (edited 02-07-2009).]

Nice write up....thanks for the info