Removing Old Door Hinge Bushings

[Fonz54]

Hi All,

I have been unsuccessfully attempting to replace my old gnarly door hinge bushings. Soaked them several times with PB Blaster and used the removal tool provided with the new Delrin bushings and a BFH (Four Pound Line Hammer). Was wondering if anyone has had to drill out the old bushings or possibly use an easy out? I saw a video on line that showed the poster using a cold chisel to peel back the top collar of the old bushing but that looks like a recipe for disaster. Can anyone provide some advice here?
Thanks,
Fonz

 

[jchadscud]

I did two Texas TJ’s and the old popped right out with the tool and a regular hammer.

I did see some people using the drill method and said that helped. They didn’t have to fully drill, but while drilling the twisting action freed up the rust and then they used the tool.

Either way, cut some cardboard and use blue painters tape to attach it to the body masking off the area around the hinge in case you slip with a tool. It’ll save your paint.

 

[Fonz54]

I did two Texas TJ’s and the old popped right out with the tool and a regular hammer.

I did see some people using the drill method and said that helped. They didn’t have to fully drill, but while drilling the twisting action freed up the rust and then they used the tool.

Either way, cut some cardboard and use blue painters tape to attach it to the body masking off the area around the hinge in case you slip with a tool. It’ll save your paint.

Thanks, I did the cardboard and painter's tape trick. I am going to try using the drill later today. The old bushings are pretty corroded.
Fonz

 

[Mike_H]

I had to pull mine off the door entirely and use a drill.

 

[Drizit]

I used a drill bit to thin em out a bit, then used a slotted screw driver to bash the lip in and then used the screwdriver to pry it off the side walls into the center of the hinge opening. It took a couple hours to do both. I wish I had protected the tub as described above as I rubbed the paint with the drill chuck.

—
There must have been a time
when we could have said no.

 

[cliffish]

I lightly drilled mine out.....the "tool" did not not work with my NE TJ but the end result was great.