Tools You'll Need:
* Punch: A slightly smaller diameter than the hinge pin. A drift punch is ideal. Avoid using a screwdriver as it can damage the pin.
* Hammer: A ball-peen hammer is best, but a regular claw hammer will work.
* Penetrating oil (PB Blaster, WD-40, etc.): This will help loosen rusted or stuck pins.
* New hinge pins: Make sure to get the correct size and type for your Cavalier's year and model.
* Gloves (optional but recommended): To protect your hands.
* Shop rags: To clean up any oil or debris.
Steps:
1. Preparation: Open the door fully. Apply penetrating oil liberally to each hinge pin. Allow the oil to soak in for at least 15-20 minutes, or even longer if the pins are particularly stubborn. Reapply the oil as needed.
2. Remove the Hinge Pins: Position the punch on one end of the hinge pin. Gently tap the punch with the hammer. Work your way around the pin, tapping lightly, until it starts to move. If the pin is seized, you may need to apply more penetrating oil and/or use more force (but avoid damaging the hinge). Once you've started the pin moving, continue tapping until it's completely out. Repeat this process for all the hinge pins on that door.
3. Inspect the Hinges: While the pins are out, inspect the hinges for any damage or excessive wear. If the hinges are damaged, you'll need to replace them as well.
4. Install the New Hinge Pins: Lubricate the new hinge pins with grease (a little goes a long way). Carefully insert one end of the new pin into the hinge. Gently tap the other end into place with the punch and hammer. Avoid hitting the pin too hard, you just need to seat it properly. Again, repeat this for all hinge pins.
5. Test the Door: Close and open the door several times to ensure it operates smoothly and the new pins are securely in place.
Important Considerations:
* Stubborn Pins: If a pin is extremely stubborn, you might need to use a slightly larger punch, but be extra careful not to damage the hinge. Consider using heat (carefully!) to expand the metal slightly, making the pin easier to remove. However, excessive heat can damage the hinges.
* Hinge Wear: If the hinges themselves are worn or damaged, replacing only the pins won't solve the problem. You'll likely need to replace the entire hinges.
* Year and Model: The exact procedure might vary slightly depending on the specific year and model of your Chevy Cavalier. Refer to a repair manual specific to your vehicle if you encounter any difficulties.
* Safety First: Always wear safety glasses when working with tools.
This process is relatively simple, but if you're uncomfortable working on your car, it's always best to take it to a mechanic. Remember to always prioritize safety and take your time.
