Replacing winshield and door hinges

[DrumMetal6]

Replacing windshield and door hinges. Old windshield hinge has a spacer in the hole. New one does not. If I install the new one without. Spacer then it slips in easy, if I try it with the spacer then I need to hammer it in Which is the right way to do?

Attached are two pictures if the old windshield hinge with the spacer, and one picture of the new windshield hinge without the spacer

 

[toximus]

Is that for the door or windshield?

 

[Willys LJ]

Those look like door hinges to me. I'm pretty familiar with them as I'm going through the door hinge bushing replacement battle right now. Those old bushings really don't want to come out of there and I really don't want to have to take the hinges off the tub.

 

[DrumMetal6]

I just had the new bushings delivered today so will see how they fit this weekend. I was able to get the old bushing out by using a nail punch to hammer through the hole. Something like this where it fits into the hole but the head is bigger so that pushes out the bushing when hammered: https://www.amazon.com/dp/B01MYRNIRU/?tag=wranglerorg-20

 

[Willys LJ]

The bushings on mine had pretty much become one with hinge brackets. Even with the fancy tool, I couldn't get them budge even after a week of soaking in Kroil. Time to start reaming them out.

 

[Goatman]

Have you tried using a hyd press? Get a proper sized bolt or piece of round stock and they should press out no problem.

 

[Willys LJ]

Have you tried using a hyd press? Get a proper sized bolt or piece of round stock and they should press out no problem.

Don't have access to a press. Even if I did, I'm very reluctant to take the hinges off of the tub. The last time I tried to remove some of those torx screws, I ended up having to drill out and re-tap about half of them.

I got one more pass with the hand reamers to take the holes up to 7/16" left to go on the driver's side before I can put in the new bushings. Then it's over to the passenger side. Those cheap chinese hand reamers work good if you don't get in a hurry with them.

 

[Willys LJ]

It just dawned on me that I should have got an extra long 7/16" drill bit and just drilled them out from above.

My "machine shop - fu" is rusty.

 

[Willys LJ]

Got the doors back on now. When I took the doors off in the spring, I didn't pay much attention to the pins and stored the doors in our dry basement. The pins were badly corroded and I spent about 20 mins on each pin with some strips of cloth backed 40 grit, smoothing them back out to where they'd fit in the bushings. I suspect that was the main culprit as to why I had such a hard time getting the doors off.