So this is gonna be quite the beast of a post/story but I'll keep it brief as possible. First I'm new to WF and owning a Jeep, they have always been in the family but I've been into the sports and muscle cars up till this point. I got into a heck of an accident where a denali decided to come into my lane and was outta work for near 3 months. Spent sometime researching cars ended up driving a buddy from works Jeep and fell back in love with the vehicle. Anywho bought a 2000 tj w/hardtop some KC foglamps on the bumper and stainless everything well almost the PO did do some work to it. Nothing major like a lift what have you. From the DMX and and 50 cent CDs I found under the carpet I reckon it was a a younger person than old. It has some scratchs minor rust on the under-body nothing a wire brush, some time and POR-15 can't handle. It had 100,000 on it so not that bad for a 12 year old car I'd say. And is in surprisingly good condition I paid 7800 for it. Inspections for life and title transfer included.
So its summer why have a jeep if the doors don't come off? So i go to take them off driver side was a little sticky but came off with a good lift. The passenger side though was a much different story. I tried PB blaster, WD-40, Liquid wrench letting them soak spraying every 4 hrs or so for like 4 days. I tried initially after like 5 mins to lift but no luck but decided to keep soaking that it may just need time to penetrate. No luck I tried cardboard and a hammer giving good wacks praying to the heavens my aim was ok. No luck with that. I tried sitting on cinder blocks with my legs underneath rocking back and forth while lifting no luck. Tried to jack it up with a jack 2x4 and a folded towel, this one scared me the most. I'm 6'4'' 245 pounds Im not Hercules by any means but not at all weak. I tried ignorantly lifting it with all i got no luck. Even got my bro to swing the door as i lifted. No luck! At this point the the pass. door was knocked out of alignment. So I try to loosen the hinges to set the door atleast back to center. Darn things are stripped. Get the dremel and my biggest flat-head no luck. Finally I took off the mirror the PO didn't replace the top hinges to stainless why no clue? Those were a little stripped but no big deal.
NOTE: The top hinge is still attached to the windshield hinge mount on the Jeep.
I tried hammering the ever loving $h!t out of it no luck hinge wont budge. PB Blaster throughout all of this and still spraying them, did it 20 mins ago. So both doors are off now but not like I would have wanted. So I then drilled out the lower hinges hex bolts. Drilled till the bolt heads poped off. Just like normal took off the hinge. The PO never put a sealer behind the hinges so rust everywhere got the wire brush and sand paper out took care of that looks great. now the mount which the bolts actually screw to is rusted pretty good. ( the part that is inside the door.
I read a post saying to take a 1/4 bit and drill straight down and that should do it. Well I did that to now I have one that has no thread (easy fix) its drilled out all the way through but looks like crap mainly due to the Craftsman drill out (grip it looking extractor) that broke off inside. Idrilled that one out all the way. I know this hinge issue is a common with Jeeps.
At this point I have one of the holes drilled out one waiting to be and one in which i wasn't centered and drilled the screw making an angle and a mess. The screw is still inside. and one screw still waiting. I have yet to look at the drivers door or play with it. I assume the lower hinge is rusted the same as the passenger side door is. Hopefully that all makes sense.
1. My passenger side hinge/pin how do I go about getting it out? It doesn't look bent but my brother suggested the thought it might be broken.
2. What should I do about the internal mount for the Hinges? just keep drilling the holes out and re-thread? Mind this thing is rusted!!! I have searched High and low with no luck in finding where to buy a new mount.
( I imagine the drivers side lower hinge had no sealer put on it as well so I'd reckon i will have to drill those out to and there's prolly the same rust issue behind it. There is no rust behind the factory hinges which he left. But did strip the torx for me.)
I am lost and worried im just digging a deep hole. Im driving with no doors which is fine till it down pours.
Please help with what I should do let me know if there are any questions needed to further help you diagnose what i should do.
much thanks Nick