a How to repair contour hinge bushings

[sdowney717]

the ford dealer does not have bushings for sale.
I searched and could find no information as to repairing the hinge.
To repair your old hinge is very simple

Get Dorman HELP product number 38381. I found this at Advance Auto parts
This will give you 3 pins and 6 bushings of which you can theoretically repair two pins. the other pin is tiny and you cant use it. One pin is too long, but you can shorten it with a grinder blade.
you will have to slightly enlarge only 2 holes in your existing hinge set.
one for the pin at the bottom and one for the bushing at the bottom, the other 2 holes are a perfect fit.
the contour has a stepped pin and bushing, the smaller hole and bushing are at the bottom.
you will need 2 drill bits and a drill.
You must remove the hinge, so support the rear of the door when unbolting a hinge. the bolts are the hardest part where they attach to the car frame. They should have made both door frame bolts screw in from the inside of the car, but one is on the inside and one on the outside. The bolt on the outside I used a 3.8 box end wrench and with some dexterity, managed to remove and install it ok. The inside bolt, just pull away the plastic molding around the hood release, unscrew the fuel relay and remove the small steel panel and you can get to the bolt. (Driver side)

The reason you have to pull the hinge off is the pin is swedged into the hinge and takes some force to remove. When you got the hinge off, use a long socket to support it while you hammer out the pin. Use some PB Blaster rust buster to help get it apart. After drilling and fitting the new bushings, the new pin will hammer in perfectly and swedge itself fine into the hinge. grease it well so it will last. Use the short pin in the kit.

[sdowney717]

sorry that is a 10 mm bolt head.
Ford dealer sells a new hinge for 60$ or a pin for 17$ but no bushings are available.
the dorman help hinge kit is 10$ so with just a little effort you save a lot of money.