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Discussion Starter #1
Hey everyone,

I have an 08 Sahara 2Dr. I bought it used and went to go remove the doors today but they would not lift off the hinge after I removed the bottom bolt. I am guessing the previous owner never removed the doors and 7 1/2 years later it is probably a little rusted inside.

Has anyone had this issue before? Any help on how to fix this and get the doors off?
 

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This is brought up periodically on here and other forums. May need to spray hinges with PB Blaster. Here is a video and some links. Do yourself a favor after you have success. Get the Delrin hinges. JEEP DELRIN DOOR HINGE LINERS : TMR Customs, Custom Fabrication Components for Offroad Vehicles Good luck.

https://www.youtube.com/watch?v=XTyiVZSX_xg
http://www.wranglerforum.com/f274/doors-stuck-98781.html
Any suggestions for removing stuck doors? - JeepForum.com
Wtf doors stuck? - JKowners.com : Jeep Wrangler JK Forum
 

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Yes. As Dr.E mentions, once Off install the Delrin inserts or the removal nightmare will be a repeaing dream.
The OE inserts rust up and bind the door pins.
Jacking and a penetrating oil is the only way to get them out and off.
Getting the OE inserts out will be an exercise in remove and replace no way to or reason to try and get them out in reuseable condition so have the Delrins on hand first.
 

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Discussion Starter #5
Thanks everyone but it didn't work.

After removing the nut I sprayed from the bottom with PB blaster for two days in a row. I even tried to tap the bolt from the bottom with a hammer and screwdriver but still was unsuccessful.

Any other suggestions?
 

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The PB blaster is not getting all the way up if you are shooting it from the bottom.

I would shoot the top of the hinge with PB, then the next day use a floor jack and a piece of wood. Slow and sure wins the race. Jack up the wood to the bottom of the door and jack a few more times after that. Not too much. Then slowly wiggle the door back and forth. After a minute or so you should see the pins start to come out. Jack a little more, spray a little more PB and continue....slowly. At about half way up the pin should totally release itself.....don't let the door fall!

Rinse repeat. Slow and steady.
 

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I second everything everyone else has already said about working the PB in there but you are most likely going to have to use the floor jack method as well. I bought my used and it seemed pretty evident they had never been taken off before so mine were a royal PITA too. Only other thing I found in other threads that hasn't been mentioned for some reason sometimes you have to find a sweet spot for how far the door is open to apply the force just right, can't say it was true on all of my doors but it does seem to be easier at about 2/3 the way open.
 

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You've gotten All good advice and All I'll add is - as much of a PIA it is.... It's worth it. And. You'll not have to do it again if you then install the Delrins.
 

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When spraying PB Blaster, rotate the door back and forth. Be generous. That should help. I also saw a post where someone cracked the door open and used a 2x4 above the door sill and below the door to pry it up.

*This post is in no way condoning any advice given and not responsible for any damage caused.
 

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If it's still really stuck you might have to use a jack and a 2x4. I've done this a couple times. Put the 2x4 on the door as close to the hinge as possible inside the skin and on the flat surface of the bottom of the door. SLOWLY jack up. You should have a friend help. When the hinge lets loose it's quick. Last piece of advice, but the Delrin bushings!
 

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It would be great if you could make a "little bowl" around your hinge maybe Aluminum foil and gorilla tape that could pool the PB blaster around the hinge opening so it really gets down in there.
 

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Thanks everyone but it didn't work.

After removing the nut I sprayed from the bottom with PB blaster for two days in a row. I even tried to tap the bolt from the bottom with a hammer and screwdriver but still was unsuccessful.

Any other suggestions?
You said removed "the nut", there are two nuts.

I just got my fronts off this last week. I wd-40 them at night. Wouldn't budge with a 2x4 and jack. Next morning I tried again. Jacked it up about 3-4 inches. Slowly it started and then boom it came off quick, fell into the vehicle. Damn it. Two tiny paint chips about the size of a bb. The other side same thing only I was ready and caught it.
 

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ps... be careful. the door can get damaged if you aren't careful. as it lifts pay attention to body/door clearances.
 

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I don't remove my doors that often and they get stuck.
What's worked for me is to remove the strap, un clip the harness and of course remove the hinge nuts. Open the door about 30 degrees, grab the bottom of the far end of the door and work it up and down like it's your first girlfriend. And just like back then, that puppy will pop right off. So have somebody close to support the hinged end when it works free. Try different degrees of opening to work it from a different angle if it doesn't break free on the first couple try's.
 

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Thanks everyone but it didn't work.

After removing the nut I sprayed from the bottom with PB blaster for two days in a row. I even tried to tap the bolt from the bottom with a hammer and screwdriver but still was unsuccessful.

Any other suggestions?
Penetrating fluid, floor jack, some boards and a rubber mallet.

You already mentioned the penetrating fluid. Try applying it from the TOP of the hinge and let it run down as you pivot the door open/close a few times.

Let it soak several minutes and then get out the floor jack and some boards. Position the boards on the jack like in the pic below and just apply enough jacking force so the jack holds the boards against the door plus a tad more.

Tap on the bottom of the door in the area shown. Keep tapping and you should see the hinge pins start to rise. You may have to increase the jack pressure a bit as the door rises away from the boards. Apply more fluid as the hinge pins start to rise.

When the pins are halfway out of the hinge, lower the jack and move it out of the way. Be careful to not push the pins completely out of the hinges with the jack unless you have a helper holding the door upright. You should then be able to remove the door the rest of the way by hand. Maybe wiggle it back and forth a little as you pull it up.



 
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