New Door Hinge Pin Won't Seat

[tucsonjwt]

I am installing new door hinge pins in my 83 C20 and the Dorman brand replacement hinge pin won't seat completely into the top of the hinge. Is it necessary for that pin to come into contact flush with the top of the hinge? It is in the hinge tight, but it appears to be slightly to large a diameter to pound down flush. Dorman p/n 703-264 for GM cars/trucks. See pic.

[SeanPaintsFlames]

Bigger hammer; maybe some heat.

[tucsonjwt]

The Dorman hinge pins are 9.44 mm at the top of the knurled cap end, and 9.32 at the bottom of that knurled area where it should seat into the top of the hinge. The opening in the hinge is 8.41 mm, so even though I have been whacking it with my mallet - it is not going to seat - close to about a 1/16" difference. Does GM still sell OEM door pins and would they be a closer fit? Dorman is all I have seen for sale.

[tucsonjwt]

Fine print on Dorman part listing, even on oehq.com (Delco parts source):
703-264

[Door Hinge Parts]
Door Hinge Pin & Bushing Kit - Boxed $3.96 $1.95
Door Hinge Parts;{Front; Door hinge hole reaming may be Reqd for installation, 1 Per Veh};DOOR HINGE PIN KIT; Years: 1980-1986;

Has anyone had to ream their hinge holes to install door pins, and if so, how much did you ream them (what size reamer did you use). Seems like you would still want a snug fit.
Thanks.

[lilpoindexter]

I used classic parts, they went in a with a little tapping

[primrrd]

I used to replace a lot of these on the c10 and c1500 style trucks.
They made smooth stock size bushings and the fluted style bushings that could be used when the hole for the hinge pin had worn and wallowed out. I have a drill set that I wrote the size bit on the case that worked for me and walked out to the garage to check it. (I'm pretty sure I was using GM parts for the replacements)
I had wrote: "31/64 for GM fluted bearings "
(on my set this is the one size smaller than 1/2 inch)
this opened up the hole enough to drive in the fluted bushing without damaging it. I think i may have even dressed the stock hole occasionally with a round file to get the smooth bushing to fit in without too much hammering too.
Now the "kit" I would buy came with new pins and bushings and the little retainer, so I never had any trouble with the pin not seating.
Best of luck..

[tucsonjwt]

Thanks for the response. I am looking at hinge pin kit from The Filling Station which seems to cover every GM vehicle since the Great Depression (GM-1081K).
The holes in my hinges are not worn out, so I got the smooth bushings in easily and I don't need the big grooved bushings. Do you think these would slip into the mating grooves in my factory hinges? .34" is about what I measure the opening of my hinges.

(http://www.parts123.com/parts123/yb....Z5Z5Z50000014x

I would prefer to have the grooves on the tops of the new hinge pins fit properly into the mating grooves of the hinges. Wouldn't just jamming the grooved tops of the pins into the smooth steel reamed out openings of the hinge cause the pins to work loose eventually?

[RandyP]

Pins and bushings are still available through GM, and they are fairly cheap.

[tucsonjwt]

Local Chevy dealer says GM no longer supplies the hinge pins, just the whole hinge with pins installed. Does anyone have the GM part number for the hinge pins so I can look online? Thanks.

[RandyP]

Hinge pins # 20046147 lists for $4.47 each. My local Tulsa dealer shows to have 44 of them, he said Houston shows 78, Nashville shows 102... they are not getting hard to find nor are they discontinued.

[tucsonjwt]

Thanks Randy. My local Chevy parts counter folk are too lazy too look up the part numbers and availability as usual. I found them at oehq.com and ordered them just now: p/n 20046147 for the pin (sold 5 per pack) and p/n 9721917 for the bushing (sold 20 per pack). I hope they are a good fit. Looks like my 83 will have to sit doorless for a week or so waiting on the parts.

[RandyP]

The only time we've ever used bushings from anywhere besides GM, is when we need oversized bushings. Even then, usually GM offers an oversized flavor of some sorts. We've also welded up the holes that have been oblonged or ruined in some fashion from neglect, and then redrilled them. Where there is a will, there is a way.

I feel your pain on lazy or dumb people at the parts counters. That is why I buy from who I do, and in most cases I have bought from them for decades. I know on my toyota and mazda and such I could buy elsewhere and get another 5% discount. But when it comes to having a smart parts person, it's just worth keeping what you have.

[tucsonjwt]

The odd thing about my hinges is that they hinge holes are really not bad - just the bushings are worn thin, causing the door to wiggle about 1/8" or less - but enough slop to prevent a steady door adjustment. The hinges themselves look mint. I probably could have saved the original pins but I decided to replace them, which puts me where I am now.

[RandyP]

But you're doing it right. If you do bushings you should do pins, it is just the right way to do it. Sort of like changing your oil, you don't reuse the old filter when you drop new fluid in.

[wazzabie]

I find I have the same problem as shown below with the GM pins. The pins do not go all the way in. Is this suppose to be a press fit?

[tucsonjwt]

No. You have aftermarket pins and you need OEM GM pins. Read deeper into this thread and you will see the OEM GM part numbers and how they are ordered.

[wazzabie]

Originally Posted by tucsonjwt

No. You have aftermarket pins and you need OEM GM pins. Read deeper into this thread and you will see the OEM GM part numbers and how they are ordered.

I have the GM pins and brushings. GM parts number on the pins are 20046147. This is for a 73-87 CK. The pins are not exactly like the originals. The head on the originals are flatter and larger. There is a H stamp on the top of the new GM pin.

Anyways my pins GM pins are not going in. I tried to use a c clamp to press them with out success.

Did you get the GM pins. Did they fit without a press?

[tinydb84]

My aftermarket pins from Dorman fit just fine with a couple smacks from a hammer. You could drill it out a hair to make it fit

[wazzabie]

I'm going to take the pin and put it in my drill press. I'll lightly sand down the sherated section near the top.
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[tucsonjwt]

Why not just get the correct pin to begin with? You will have difficulty getting a completely round, perfectly ground diameter - creating uneven wear on the pin and bushing, resulting in premature failure in the future - just my guess.

[Your41Plague12]

Use a 23/64 drill bit on the splined hole of your hinge. It will seat after that. I just did this, and the Dorman pins work great now.