Tools You'll Need:
* Socket set: Various sizes, including likely a 1/2" drive for larger bolts.
* Wrench set: May be needed for some bolts.
* Screwdrivers: Phillips and flathead, depending on the hinge design.
* Penetrating oil (like PB Blaster): Crucial for loosening rusted bolts.
* Hammer: For gently tapping things loose (use a rubber mallet if possible).
* Punch: To help drive out stubborn pins.
* New door hinge: Make sure you get the correct one for your truck's door.
* Jack stands (recommended): To safely support the door while working. A helper can also assist.
* Safety glasses: Protect your eyes from flying debris.
* Gloves: Protect your hands.
Steps:
1. Preparation: Park your truck on a level surface and engage the parking brake. If possible, disconnect the battery negative terminal to prevent accidental short circuits.
2. Access the Hinge: Open the door as wide as possible. The hinge pins are usually located on the hinge itself. You may need to remove some interior trim pieces to get better access, depending on the location of the hinge and truck's configuration.
3. Loosen the Hinge Bolts/Pins: Liberally apply penetrating oil to the hinge pins and any bolts attaching the hinge to the door and the body. Let it sit for at least 15-20 minutes (or even longer if very rusted). This will significantly help in removing them.
4. Remove the Hinge Pins: Using a punch and hammer (gently!), tap out the hinge pins. Work carefully to avoid damaging the hinge or the door. Sometimes the pins are just screws, in which case, just unscrew them.
5. Remove the Hinge: Once the pins are removed, the hinge should separate from the door and the body. You may need to gently pry it apart.
6. Install the New Hinge: Align the new hinge with the existing mounting holes on the door and body. Insert the hinge pins or screws, making sure they are properly aligned before fully tightening.
7. Tighten the Hinge Bolts/Pins: Tighten all the bolts and pins securely, but avoid over-tightening.
8. Reinstall Trim: Replace any interior trim panels you removed to access the hinge.
9. Test the Door: Open and close the door several times to ensure smooth operation and that the hinge is securely installed.
Important Considerations:
* Rust: Rust is the biggest enemy here. Be prepared to spend time soaking the bolts and pins with penetrating oil. If the bolts break off, you may need to drill them out.
* Alignment: Pay close attention to aligning the hinge correctly during installation to prevent the door from binding or sagging.
* Professional Help: If you're uncomfortable with this repair, or if you encounter significant problems (like broken bolts), it's best to take your truck to a qualified mechanic.
This is a general guide. Consult a repair manual for your specific 1990 Chevy pickup model for precise instructions and diagrams. Remember safety first! Always use appropriate safety equipment.
