You may need to replace a truck door hinge pin if your door is damaged or worn and sagging. Save yourself the expense and trouble of replacing the entire hinge by replacing just the hinge pin.
Step 1 - Purchase Replacement Pins
Truck dealers may carry replacement pins for the specific model you have, though their kits may be pricy. Look to auto parts stores and online for alternatives. Though dealer products are often worth the money, when it comes to truck door hinge pins, aftermarket products are solid.
There are many variations in sizes of hinge pins, so be sure to find one that fits the exact model and year of your truck. Kits will vary in price, but most will cost approximately $20 to $40.
Step 2 - Remove Lower Hinge Pin
Unless you have an engine hoist to hold the door in place or two other people helping you, you must change the hinge pins one at a time. Have another person or a support that will fit under the door as you work.
Use a pin removal tool (approximately $20 on eBay) or a nail punch kit to remove the old pins. You can use a hammer and nail, screwdriver, or other tool, though the process will likely take longer.
It will be necessary to allow the door to hang (supported) slightly out of alignment in order to get enough give to remove the pins. Note that the bushing/pin kit come in three parts— an upper and a lower bushing and a pin.
Step 3 - Install New Lower Pins
Put the bushings into the hinge. During this procedure, it is much easier to have a person helping you with the door rather than having a support hold the door, since it will require constant adjusting to get the bushing to seat properly.
Then install the lower pin into the top bushing, moving and adjusting the door as you go to allow the pins to slide in somewhat freely.
With most doors, this process does not go smoothly. The fit is tight, and it will likely require some force to complete the installation.
If you use a tool to hammer the pins, cover them with a protective cloth and tap gently. The bushings are prone to breakage.
Step 4 - Repeat for Upper Pins
Once the lower hinge is complete, repeat the removal and replacement process for the upper hinge.
Be sure to have the door supported mechanically during the removal, and preferably by a person during the installation of the new pins so the door can be adjusted to ease the installation.
Seat the pins to complete the process.