1. Assess the Damage:
* Squeaking/Sticking: This often indicates a lack of lubrication.
* Sagging Door: Worn hinge pins or bushings are the likely culprits. The door might bind or rub against the body.
* Loose Door: This suggests worn hinge pins or potentially stripped hinge mounting holes.
* Broken Hinge: This requires replacement.
2. Tools and Materials:
* Penetrating oil (like PB Blaster or WD-40): For lubrication.
* Grease (lithium grease is recommended): For long-term lubrication.
* Hammer: For tapping pins.
* Punch (slightly smaller than the hinge pin diameter): To help drive out pins.
* Replacement hinge pins: If necessary. You might need to specify if they're for the top, middle, or bottom hinge.
* Replacement hinges (complete hinges): If necessary.
* Socket set (metric): Possibly needed for removing hinge bolts if you're replacing the entire hinge.
* Screwdrivers (Phillips and possibly flathead): For accessing hinge pins or screws.
* Safety Glasses: Protect your eyes.
* Gloves: Protect your hands.
* Jack stands (optional but recommended): Support the van safely.
3. Repair Procedures:
A. Lubrication (for squeaking/sticking):
1. Spray penetrating oil liberally onto the hinge pins and surrounding areas. Let it soak for a few minutes.
2. Work the door open and closed several times to distribute the oil.
3. Wipe off excess oil.
4. Apply grease to the hinge pins. This provides longer-lasting lubrication than oil alone.
B. Replacing Hinge Pins (for sagging or loose door):
1. Support the door: Have someone hold the door or use a support to prevent it from falling.
2. Remove hinge pins: Use a punch and hammer to carefully tap out the hinge pins. Work slowly and evenly to avoid damaging the hinges. Sometimes you can just tap one end out, then the other end will fall out.
3. Inspect the pins and bushings: Check for excessive wear or damage.
4. Replace worn pins and/or bushings: Install new pins (if necessary). If the bushings are worn, you may need to replace the entire hinge.
5. Reinstall the pins: Tap the pins back into place using the punch and hammer. Don't force them – they should slide in relatively easily.
C. Replacing Complete Hinges (for severe wear or broken hinges):
1. Support the door: Use a support or have someone hold the door.
2. Remove the door: You'll likely need to remove the screws or bolts that attach the hinges to the door and the vehicle body. Consult a repair manual for your specific year and model Astro van to know the precise location and type of fasteners.
3. Install the new hinges: Align the new hinges correctly and securely attach them using the appropriate fasteners.
4. Reinstall the door: Hang the door on the newly installed hinges.
Important Considerations:
* Repair Manual: A repair manual specific to your 1999 Astro Van is highly recommended. It will provide detailed instructions, diagrams, and torque specifications for your vehicle.
* Safety First: Always use jack stands if you're working under the van. Never work under a vehicle supported only by a jack.
* Parts: Obtain replacement parts from a reputable auto parts store. Make sure to specify the year, make, and model of your Astro Van to ensure you get the correct parts.
If you're not comfortable performing these repairs yourself, it's best to take your Astro Van to a qualified mechanic. Replacing hinges can be challenging if you're not familiar with automotive repair.
