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  #61  
Old October 15th, 2014, 05:51
bradford0113 bradford0113 is offline
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Re: Broken door-hinge welds: cheap n easy fix!

I too am about to attempt this fix on my wife's '96 XJ. Everything seems pretty straight forward but I'm also concerned about how to remove the hinges from the door.

I am assuming that both upper and lower hinges need to be removed at the door side (torx screws). Then do the pins actually have to be removed from the hinges or can the mod be done with the pins left in place?

How is everyone else doing this?
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  #62  
Old October 15th, 2014, 15:44
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WrenchMonkey WrenchMonkey is offline
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Re: Broken door-hinge welds: cheap n easy fix!

I had already modified the hinges, to let me lift the doors off.

If you haven't (and don't intend to), I'm sure you could just unbolt the hinges from the door, remount them on the body, the bolt the door back on. It'll be more work getting the door aligned (may want to throw some fresh paint on the hinge, to mark exactly where they mount) but it'll work.

Good luck!

Robert
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  #63  
Old February 14th, 2015, 19:48
kthwds kthwds is offline
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Re: Broken door-hinge welds: cheap n easy fix!

Thank you for this posting, I am a recent buyer of a 91 two door xj , and couldn't be prouder. My doors were sagging so I researched until I found this. I am about to bolt plates on but wonder what you did to that factory hole that is about an inch in diameter, by that I mean it is a stamped hole and the plate won't sit flush . Or did it not affect anything??
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  #64  
Old February 14th, 2015, 23:58
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WrenchMonkey WrenchMonkey is offline
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Re: Broken door-hinge welds: cheap n easy fix!

I know exactly the one you mean, you can see it in my first few pics.

I just tightened the bolts and pulled the plate tight against that dimple. Seemed to seat nice n tight, and hasn't budged in years.

How old is this thread? Six years? I've driven mine daily and wheeled hard once a month, no issues at all.

(Of course, there's been no door hanging on it from Easter to Thanksgiving, so that helps...)

Good luck with it!
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  #65  
Old February 16th, 2015, 06:10
lukc22 lukc22 is offline
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Re: Broken door-hinge welds: cheap n easy fix!

Did you thread the holes in the plate, or weld nuts on it??? I need to do this exact thing.... the PO did a horrible reweld job.... Thanks for the write-up!!
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  #66  
Old February 16th, 2015, 07:48
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Re: Broken door-hinge welds: cheap n easy fix!

Quote:
Originally Posted by lukc22 View Post
Did you thread the holes in the plate, or weld nuts on it???
Quote:
Originally Posted by WrenchMonkey View Post
I ground the old welds off of the hinge, drilled a couple more 3/8" holes to bolt it to the plate, then (after test fitting everything) I drilled and tapped the plate to match.
Quote:
Originally Posted by WrenchMonkey View Post
There are no nuts: I drilled and tapped (threaded) the 1/4" plate. The bolts just thread into it.


(You could probably weld nuts if you preferred, but tapping worked pretty well for me.)
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  #67  
Old February 16th, 2015, 07:54
lukc22 lukc22 is offline
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Re: Broken door-hinge welds: cheap n easy fix!

Thank you for the reply... I just re-read this entire thread and noticed that i had skipped some before posting that... thank you again for this thread!!
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  #68  
Old February 16th, 2015, 08:09
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Re: Broken door-hinge welds: cheap n easy fix!

You're very welcome, glad I could help!

And welcome to !
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  #69  
Old September 6th, 2015, 14:01
ScandiSpeyXJ ScandiSpeyXJ is offline
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Re: Broken door-hinge welds: cheap n easy fix!

Thanks for posting this fix. I just did it to my 96 XJ, it worked great. I have an 84 cherokee chief that I will be using this fix on as well.
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  #70  
Old September 25th, 2015, 11:50
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Re: Broken door-hinge welds: cheap n easy fix!

Glad I was "pointed" at this post. Because my 93 2door is breaking the re welds, guess ripping out the "guts" of the latch wasnt a very smart thing... But it wouldn't unlock.
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  #71  
Old March 12th, 2018, 14:00
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WrenchMonkey WrenchMonkey is offline
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Re: Broken door-hinge welds: cheap n easy fix!

Like so many others, this thread was pretty much ruined when pee-bucket got greedy and broke all the links. I can't go back and edit my old posts here, but I did redo the original writeup on my local club's board.

http://www.cincyoffroad.com/forum/sh...ad.php?t=12100

If a moderator would or could add this note and link to the first post for others who come looking, that'd be awesome...

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  #72  
Old March 12th, 2018, 20:39
burntkat burntkat is offline
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Re: Broken door-hinge welds: cheap n easy fix!

Quote:
Originally Posted by derrickdrew17 View Post
Mine sags but the welds are not breaking at all its the pins wearing out.. because i can puck up and the door half moves but the body side stays put.
Just replace the pins. It's a SUPER easy job.
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-90 XJ 4.0, AW4, 231J: Clayton's longarms, RE 5.5" coils, hybrid 6" leaf pack, 33/12.50/15" MTs, Rancho 99012s and 99624s, Tera HD SYE, custom sliders, BW flares. Rehabbing with D44s, RE spring packs, RE 4.5" coils, and ACOS.
-94 ZJ: Budget boost, 31s. The wife's DD.
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  #73  
Old March 12th, 2018, 21:15
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Re: Broken door-hinge welds: cheap n easy fix!

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Originally Posted by burntkat View Post
Just replace the pins. It's a SUPER easy job.
That was nine years ago, I bet he's got it.
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  #74  
Old March 13th, 2018, 11:22
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macgyvr macgyvr is offline
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Re: Broken door-hinge welds: cheap n easy fix!

Quote:
Originally Posted by WrenchMonkey View Post
Like so many others, this thread was pretty much ruined when pee-bucket got greedy and broke all the links. I can't go back and edit my old posts here, but I did redo the original writeup on my local club's board.

http://www.cincyoffroad.com/forum/sh...ad.php?t=12100

If a moderator would or could add this note and link to the first post for others who come looking, that'd be awesome...

Members can now edit their threads.

Please fix the pics, that would be awesome!

mac 'thanks!' gyvr
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  #75  
Old March 13th, 2018, 12:36
burntkat burntkat is offline
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Re: Broken door-hinge welds: cheap n easy fix!

Quote:
Originally Posted by macgyvr View Post
Members can now edit their threads.

Please fix the pics, that would be awesome!

mac 'thanks!' gyvr
The viewer can install the Photobucket fix on their browser which will eliminate the problem entirely.
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-89 S-10: SAS, D44s front/rear. 5.7L V8. 700R4 with 4L60E upgrades. Built in my driveway.
-90 XJ 4.0, AW4, 231J: Clayton's longarms, RE 5.5" coils, hybrid 6" leaf pack, 33/12.50/15" MTs, Rancho 99012s and 99624s, Tera HD SYE, custom sliders, BW flares. Rehabbing with D44s, RE spring packs, RE 4.5" coils, and ACOS.
-94 ZJ: Budget boost, 31s. The wife's DD.
-97 XJ: Son's DD. 4" lift, ACOS, 4" spring pack, Upcountry coils, 31s
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