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Discussion Starter #1
So my 08 JK has/had a case of the sagging doors. Bought one of the bushing kits available online and had time in the shop to due two doors. They said in the included instructions to take the doors off and then drive the bushings from the bottom up from the hinge that is still attached to the Jeeps door frame. First thing is just close the door and remove the hinge bolts from the door. Due one hinge at a time. Lift the hinge out of the frame half so you can see the top of the bushing. Then I used a grinder to carefully remove the lip at the top of the bushing so I could drive it down and out. Reason instructions said up was the lip. Then just push the new bushing in and clean any corrosion of the hinge pin, put back together and move onto the next one. Then just like a face lift no more sagging doors. How cool is that!
First picture is of new bushing in place and second of a couple of corroded ones.
 

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Why not just take the doors off? If you use a small screw driver and hammer on that upper lip you can crush the bushing into itself and just push it out from the bottom.

I don’t like to mess with the paint on the door hinge bolts or break the paint seal between hinge and door face.


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Discussion Starter #3
That is a great idea. Still have two doors to go. My paint seal is corroded. I see what you mean if the paint is good. Wouldn’t want to break it either. Let you know how it goes. One of the bushings was really hard to get out. Collapsing it inwards could get it to move easier. Thks
 

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Mine were the same when I replaced the liners a few months ago. They were so corroded they wouldn’t budge.
I ended up using a flat head screwdriver and hammer to “chisel” the top lip up and inwards. There’s a tiny slit on all of the metal liners that should be you starting point. Once the lip was up I started chiseling downwards. Just find a spot you can fit the screwdriver between the bushing and the hinge and start hammering it downwards (will take a decent amount of force, so don’t be afraid to hit it).
Just keep doing this and moving your way around the bushing and it will eventually be pushed away from the inner edge enough to fall out the bottom.
One out, I sprayed a little rustoleum clear coat inside the hinges, let that dry, then greased them up a bunch before putting the new bushings in
Definitely do this with the doors off. Not sure why instructions would say to leave them on. Also grease up the male part of the hinge (on the actual door) and inside the new bushings, before putting back on the doors
 

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The tool that came with my $11 ebay kit hammered the bushings up with not much issue, I did soak them with PB blaster for a few days first....

Yeah... just take off the damn doors! Better yet, do this job some day when they are already off!
 

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My delrin replacement hinge bushing set came with a tool designed to drive out the old bushings. This was not on a 1 year old JKU but a 15 year old TJ, but the principles still apply. The kit included the four bushings and the drive pin along with a brush to clean out the hinge.

While removing the hinges one at a time will work, it's almost more of a hassle of horsing off the doors. Ironically, only one of the four original bushings had any perceptible rust on it. In fact, they were almost good enough to sand off and reinstall, which I did not do. Since I already had the new liners, they went in.

Here is a link to the instructions for the JK:
https://www.quadratec.com/sites/default/files/installation_instructions/248899.pdf
 

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Discussion Starter #7
So I did the lip suggestion. Tapped the bushing lip inwards which collapses the bushing a bit. Put the push tool in and gave it a tap. Bushings almost dropped out. Worked faster than what I did on the first two doors. Thks👍
 

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I used emory cloth to clean the pins and the hinge holes and sprayed everything down with lithium grease (per instructions), and the pins were still binding a bit in the Delrin bushings, making the doors difficult to remove. I popped out the bushings and cleaned the holes again and they were still tight, which was annoying. I ended up just covering the pins with regular old axle grease and now they don't bind at all.
 

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I used emory cloth to clean the pins and the hinge holes and sprayed everything down with lithium grease (per instructions), and the pins were still binding a bit in the Delrin bushings, making the doors difficult to remove. I popped out the bushings and cleaned the holes again and they were still tight, which was annoying. I ended up just covering the pins with regular old axle grease and now they don't bind at all.
How did you remove your bushings? When I did mine they were so corroded and rusted in that hammering them with the removal tool actually shifted my door hinge a bit. You may have to realign your door hinges.
 

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How did you remove your bushings? When I did mine they were so corroded and rusted in that hammering them with the removal tool actually shifted my door hinge a bit. You may have to realign your door hinges.
The kit had the removal tool. It's a 2017 so the bushings weren't very old. Amazing Jeep doesn't use Delrin from the factory though. So many simple things they could improve at effectively zero cost.
 

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So many simple things they could improve at effectively zero cost.
And that is what annoys me so much about Jeep. There are literally one hundred things they could do to improve a Wrangler that would cost nothing. One of them is replacing those bushings with anything outside of the aluminum ones. The world has known since the dawn of metallurgy that aluminum and steel together causes corrosion but Jeep/FCA soldiers on with that stupidity.

One day I'm going to put a list together of all the little changes that Jeep could make to Wranglers and cost them out -- I would not be surprised if they were cost neutral.

Deep breath.
 

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And that is what annoys me so much about Jeep. There are literally one hundred things they could do to improve a Wrangler that would cost nothing. One of them is replacing those bushings with anything outside of the aluminum ones. The world has known since the dawn of metallurgy that aluminum and steel together causes corrosion but Jeep/FCA soldiers on with that stupidity.

One day I'm going to put a list together of all the little changes that Jeep could make to Wranglers and cost them out -- I would not be surprised if they were cost neutral.

Deep breath.
Perhaps the plastic becomes a poor choice when its -50c outside for a few of our canucks, or soviet friends.... I'm sure Jeep isn't that stupid, right?
 

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Perhaps the plastic becomes a poor choice when its -50c outside for a few of our canucks, or soviet friends.... I'm sure Jeep isn't that stupid, right?
That's debatable. At any rate, they don't have to use the plastic ones though I haven't heard any issues involving them in cold weather. If so, there are other metals besides aluminum.
 

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Discussion Starter #14
Aluminum and steel is sometimes not a great combo. We service a lot of f150’s and quite a few times I’ve seen it where a sledge hammer has been used to break the wheels loose from the hubs when servicing breaks. You leave one wheel nut partially on so when the rim finally comes loose it doesn’t go flying. Hitting the rubber of the tire on the back side so the rim doesn’t get damaged of coarse. The rust that has formed between the two metals is quite bonding so to speak.
 

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So what delrin replacement bushings is everyone using? My doors are difficult to remove sometimes so I have been thinking about replacing the bushings.
 

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Perhaps the plastic becomes a poor choice when its -50c outside for a few of our canucks, or soviet friends.... I'm sure Jeep isn't that stupid, right?
Possibly, one of the primary uses DuPont lists for their Delrin 150 is winter sporting goods but their data sheet (for the general family of plastics called POM) says it gets brittle at about -40C. There are other options, though. PTFE is pretty slick, too, and some variants are insanely stable from about -250C to 400C. You know, in case you run trails on the surface of Venus.

I'm sure they could do better than the crappy guaranteed-to-corrode aluminum foil insert we all bought.
 

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im starting to consider just replacing the door hardware as well, hinges and body mounts, and then pop in the new bushings I got in those.


Thoughts?
 
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