Just finished replacing the drivers side upper hinge pin with a big Thank You to jetman for his excellent instructions with photos and his bolt "helper" idea, it worked really well! Also used theogre idea to install an Oiltite M12 nylon washer to increase service life of door hinge and improve door operation.

Getting the old hinge and bushings out was a real challenge, but I did it without removing the door. Installing the new hinge pin was a snap (or I just ended-up being lucky on my first try).

I purchased a Dorman "HELP" Door Hinge Repair Kit #38402 instead of the suggested #38407 as the collar length and color exactly matched the existing hinge pin. Just had to grind down the tip a bit to match the length of the existing pin. Also purchased a bushings kit as the bushings that came with the #38402 kit had smooth collar walls instead of the grooved walls. I filed-down the grooves a bit so the bushings would fit more easily into the door hinge holes, then used the bolt "helper" idea with a wrench and ratchet to press down the bushings into place.

I lined-up the holes using my floor jack and installed a temporary 1/4" x 1 1/2" long bolt in the top hole, then drove the new pin up into place through the nylon washer, using a small hammer. It ended-up going in quite easily. Then replaced the outer door skin torx screw and I was done. The door no longer sagged, lined-up nicely with adjacent body panels, and now closes properly. Yeah!

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New owner of 88 Fiero GT and second time owner of 1985 Fiero GT. Bought my first fully loaded Fiero GT new in 1985. Fiero's are Fabulous, Fix'em and have Fun! Note, Avatar picture is Mr. Bean (not me, ha ha).

quote Originally posted by canfirst: Just finished replacing the drivers side upper hinge pin with a big Thank You to jetman for his excellent instructions with photos and his bolt "helper" idea, it worked really well! Also used theogre idea to install an Oiltite M12 nylon washer to increase service life of door hinge and improve door operation. Getting the old hinge and bushings out was a real challenge, but I did it without removing the door. Installing the new hinge pin was a snap (or I just ended-up being lucky on my first try). I purchased a Dorman "HELP" Door Hinge Repair Kit #38402 instead of the suggested #38407 as the collar length and color exactly matched the existing hinge pin. Just had to grind down the tip a bit to match the length of the existing pin. Also purchased a bushings kit as the bushings that came with the #38402 kit had smooth collar walls instead of the grooved walls. I filed-down the grooves a bit so the bushings would fit more easily into the door hinge holes, then used the bolt "helper" idea with a wrench and ratchet to press down the bushings into place. I lined-up the holes using my floor jack and installed a temporary 1/4" x 1 1/2" long bolt in the top hole, then drove the new pin up into place through the nylon washer, using a small hammer. It ended-up going in quite easily. Then replaced the outer door skin torx screw and I was done. The door no longer sagged, lined-up nicely with adjacent body panels, and now closes properly. Yeah!

We are about to tackle this next. What is the additional bushing kit that you purchased?

Welcome to the madness! OP knows the madness since his sig says he got an 85 gt new.

I don't think I have seen that door hinge pin thread, could you point me to it?

Here is the link to jetman hinge pin replacement
https://www.fiero.nl/forum/A...060206-2-066102.html

The Help bushings kit number is 38374 there are 8 bushings in the kit but you only need the bushings with the grooved collar.
Let me know if you need any further assistance.
Good luck!

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New owner of Silver 88 Fiero GT and second time owner of 1985 Fiero GT. Bought my first fully loaded Fiero GT new in 1985. Fiero's are Fabulous, Fix'em and have Fun! Note, Avatar picture is Mr. Bean (not me, ha ha).

many thanks for the help and happy fiero'ing!