How NOT TO fix a GM door hinge

A video that explains the failure of the dorman replacement hinge and goes over what I think would be a better alternative fix.

[@josephastier7421]

Thanks for posting. Most people only share their successes. You teach a lot more when you show the times when you had to fight for it. We've all been there.

[@kylesalem-fuson8012]

Just finished the passenger side on a 99 c3500 I replaced 3/4 brackets. On the driver side I will only be replacing the brackets that contain the bushings. The problem on the body side lower, and door side lower, was the the spot welds were totally not in the same location as the new bolt holes I made a cardboard template for the body side upper, drilled em 1/2 and chisels the hinge right off But if you looks at the back side, as you can on both lowers, the spots welds are just not even close to the new bolt holes.

[@Micktz28]

Thank you for posting this video. I was just about to buy the same hinges for my S10. I think your idea about the washers is the best fix.

[@Bbernhardsr]

If you do it can you tell me how it went?

[@Micktz28]

@@Bbernhardsr I sure will.

[@stevegraham121]

I had these on my truck for awhile now. They work great for me. The threads on my hardware weren't flat like that. They do suck to install though.

[@johnm840]

Thanks for the info.

[@normansanchez8730]

Thanks for the heads up.

[@calred6698]

Did the same thing just now! Took 2 hours, a reciprocating saw. All the way up to .5”

[@DavidM-vb1uy]

Oh man you nailed the experience perfectly, I feel your pain brother! Crap, Crap, Crap...And if it's not a Bunch O' Crap it's a Bunch O' Shite!!!

[@Bbernhardsr]

Exactly!!!

[@doranyahsharahla7262]

Thank you was just about to purchase dorman🙏🏿

[@Bbernhardsr]

Yeah man I think I would try to weld some washers or something on the factory hinge. This dorman product is junk.

[@doranyahsharahla7262]

Bbernhardsr Good looking out man thank you I’m going on LMC Trucks to order there parts or just get dealer manufactured ones

[@Bbernhardsr]

@@doranyahsharahla7262 let me know what you find. I would like to know about other options.

[@doranyahsharahla7262]

Bbernhardsr will do

[@BuhlouBear]

I sympathize, crummy parts don't make frustrating work feel "finished".

[@davidjordan780]

I almost went that route, thanks for the warning. I won't try it that way, I'll repair my worn out hinges . Mine are almost worn through the edge on the driver's side

[@Bbernhardsr]

Trust me, you will be better off!

[@upsidedowndog1256]

Spot welded wear items like door hinges simply make no sense! I bet more than a few of those trucks got scrapped due to that problem!

[@Bbernhardsr]

Believe me, I was getting nervous. Especially when the A pillar started deforming because of the air chisel. Honestly I don't know how I managed to get everything back so straight. The big man upstairs must have been guiding my hands.

[@upsidedowndog1256]

@@Bbernhardsr Yeah, considering those issues you dealt with it did turn out pretty straight.

[@Bbernhardsr]

Thanks for the kind words. It is one of the most horrific hack jobs I have ever done. 😖🤪

[@davediamond1742]

add the part no to the description in the video heading . i agree this a pore GM design from the get go! a rotor cut bit may have helped . but this is a issue on allot of gm trucks . Im about to tackle a repair my self and I think a junk yard hinge is the route i am going to take , instead of the dorman garbage . and weld it back on .. cheers to al and if someone has a better fix please post it DD

[@haroldseaman4243]

I have a 2000 Sonoma and the same hing one of the welds broke and the door sags. I was thinking of doing the same thing not now thanks for the info!! How did you get access to the inside to put the plate did you have to remove any of the dashboard?

[@Bbernhardsr]

No if I remember right you get access after you get the emergency brake assembly out of the way. The top plate is a real pain in the arse! This kit really sucks. I would go to a scrap yard and try to get a hinge there and weld it on your truck.

[@Bbernhardsr]

Heck if all that is wrong with yours is the weld broke I would just take the door off and knock the hinge back where it needs to be and weld it back.

[@haroldseaman4243]

Thanks for the reply I was wondering about doing that didn't know if I need a specific welder. Was thinking of drilling a hole use two big washers a bolt and nut to squeeze it back together. Kind of dumb they didn't use bolts in the first place lol

[@Bbernhardsr]

@@haroldseaman4243 no specific welder needed. Run what you brung 😏. It is a bad design for sure! Although I guess if bushings were replaced more regularly then the hinge wouldn't wear out.

[@haroldseaman4243]

Thanks tremendously for you're time and info much appreciated Pal!!!!!

[@crapschamp9986]

I think the easy way to repair a worn oblong hole in a door hinge is to get the same body hinge from the junk yard same year make both size holes fill in the hole with a welder than tac weld the old part on the car or truck i have a 97 s10 use the old part to locate the part on the truck and it should be in the corect location.you could have used the new part for this .as long as the chinese made it the same its hard to say with them.but a junk yard part if the bearings are ok and the steel part not worn should be a good fit mike the bearings and hole size to drill needed size the Dorman pin kit has the size on them big hole .530 small .490 i just need to fix the big hole ,also check the bearing for roundness got one bent and one not.another 7 bucks owell.im taking a washer and practicing welding with a small stick welder the same thickness to get it right the on truck.im also tracing the hole to get a location part thats not worn and marking because you can see were the hole wore and not .i don't have the braket from junk yard but a cordless cutter or saw all they may give it for free if you get them off just mark them top bottem hole this side up take a piture for after to tac weld same way after you fill the hole in some grind flat then drill then make repairs gring tack off paint and put back together.

[@crapschamp9986]

Did some practice welds on the washer worked nice 110 hobby arc looks 👍 truck next.

[@AndrewJones-uh7ot]

U made it happen .....lol just did same shit I welded mine in

[@Bbernhardsr]

Lol I take it that you didn't have much luck with the dorman kit either?

[@milesmoore8705]

I have a 1994 Chevy Suburan. I would scrap the truck but put a darn new motor in it. I like your washer idea, that just might work so I do not have to cut off the hinges.

[@Bbernhardsr]

If you try it let us know how it works. If you can I would use a hard metal like grade 8.

[@CCROSS5882]

$80 dollars parts $500 labor

[@Sh0ck556]

If I had to do it all over again I would have never bought an s10. Damn this thing!

[@Bbernhardsr]

Yeah overall I like the truck. I just wish it had a better designed door hinge.

[@Sh0ck556]

I cut the old hinge off and installed the new one which I couldn’t for the life of me get it aligned properly so I cut it off and installed the old one back on and added washers like you suggested. Still sags but not nearly as bad.

[@Dubblesteel]

Sorry you had such a hard time, this is a teaching moment, DON'T DO IT

[@bobbybishop5662]

Dorman makes some good items but they also have items like this that area complete garbage.

[@XqeDiosxqe]

Weld them in place next time

[@Bbernhardsr]

Weld what in place?

[@CatFishMarmite]

I wish I would’ve watched this a month ago

[@Bbernhardsr]

Oh no! Did you buy the dorman hinge like me?

[@CatFishMarmite]

Bbernhardsr lol yeah dude for a customer vehicle, ordered them off rock auto and now I can’t return them. I’m gonna put a floor jack under it with a block or wood and jack the piss out of it and see if I can get it to line up

[@Bbernhardsr]

@@CatFishMarmite man sorry to hear it. I guess if worse comes to worse then you could get a salvage yard to cut you an A pillar with hinges. Cut out what you need and weld it to the customers car.

[@CatFishMarmite]

Bbernhardsr I ended up just putting a jack and a board under the door and cranking it up. Door shuts perfect now. The trick is to have the door open just enough so it clears and doesn’t bind on the pillar. I was doing it with the door open half way and it didn’t tweak the hinges enough

[@Bbernhardsr]

@@CatFishMarmite that makes sense to me. Glad it worked out.

[@jonsworld5307]

not really parts problem factory welded the door to much should of grinded it or used sawsall new parts same as oem why they wear out there junk if you look up toque specs the bolts want strip 18 pounds btw about same as oil drain plug

[@rcaddict7842]

did a bunch of those kits without issue Not the hinge that was the issue if you have to read the directions you should not be doing the job

[@Bbernhardsr]

Sounds to me like you are a person who only learns by trial and error. Guess that is fine for you if you don't mind screwing shit up the first few times you do it. Me on the other hand I like to try and get it right the first time. I don't have the time for doing repeat work and I don't like wasting money. But hey, it sounds like you found a system that works for you so keep at it!

[@beardedforlife3740]

If you have to read the directions you should not be doing the job? Do you know how stupid that sounds

[@StripMallMurder]

The bolts that come with replacement hinges are GARBAGE. Get 'Grade 8' steel bolts from the hardware store.

[@Bbernhardsr]

Your right they are garbage. Quite frankly I think the whole kit is garbage.

[@XqeDiosxqe]

Made in China ? That was the problem .

[@Dubblesteel]

Bad design by GM

[@Bbernhardsr]

Even worse design by dorman

[@johnwargo2590]

Ford Ranger, bolt on hinge. Why GM welds a wear item like a door hinge on just tells you they don't care much about the poor slob who has to service this crap.