Tools You'll Need:
* Socket Set: Various sizes, including metric and possibly SAE. You'll need to determine the exact sizes based on your vehicle's specific bolts.
* Wrench Set: Again, a mix of metric and SAE sizes might be needed.
* Screwdrivers: Phillips and possibly flathead.
* Pliers: Needle-nose pliers can be helpful for reaching tight spaces.
* Jack Stands (Crucial!): Absolutely necessary for safety. Never work under a vehicle supported only by a jack.
* Jack: To lift the vehicle.
* Wheel Chocks: To secure the wheels on the ground.
* Penetrating Oil (PB Blaster or similar): Essential to loosen rusted bolts. Apply liberally and let it sit for a while before attempting to remove anything.
* Torque Wrench (Recommended): To tighten the new hinge bolts to the manufacturer's specifications. This prevents damage to the hinge and door.
* Shop Rags: To clean up and protect surfaces.
* Safety Glasses: Protect your eyes from flying debris.
* Gloves: Protect your hands.
* New Hinge(s): Make sure you have the correct replacement hinge(s).
Procedure:
1. Safety First: Park the Explorer on a level surface, engage the parking brake, and chock the wheels. Jack up the vehicle and securely place it on jack stands. Never work under a vehicle supported only by a jack.
2. Prepare the Door: Disconnect the door's electrical components (wiring harness for power locks, window, etc.). Carefully unplug each connector. Take pictures or make notes to remember where everything goes during reassembly. You might also need to remove the interior door panel to access certain bolts and wiring.
3. Access the Top Hinge: To access the top hinge, you’ll likely need to remove a portion of the door frame trim (the plastic or metal piece around the hinge). Carefully remove any trim covering the top hinge bolts.
4. Remove the Top Hinge: There will be bolts attaching the top hinge to both the door and the body. Apply penetrating oil liberally to these bolts well in advance. Use the appropriate sockets and wrenches to remove these bolts. Work carefully to avoid stripping the bolt heads. The hinge might be slightly stubborn due to rust or age. If a bolt breaks, you might need to drill it out.
5. Install the New Hinge: Once the old hinge is removed, carefully clean the mounting surfaces on both the door and the body. Install the new hinge, ensuring proper alignment. Insert the bolts and tighten them *slightly*.
6. Reinstall Everything: Re-attach the door panel, reconnect the electrical components, and reinstall the trim.
7. Align the Door: Once everything is reassembled, carefully lower the vehicle. Check the door alignment; it might need slight adjustment. You might need to adjust the door striker, the latch, or the hinges to get perfect alignment.
8. Final Tightening: Once you're sure the door aligns properly, finish tightening all bolts to the manufacturer's specified torque.
Important Considerations:
* Rust: On a 1991 vehicle, rust is a significant possibility. The penetrating oil is crucial. If bolts break, you'll likely need to drill them out and potentially use bolt extractors.
* Alignment: Getting the door aligned perfectly after reinstalling the hinge is critical. Small adjustments might be needed to the striker plate or hinge bolts.
* Repair Manual: A repair manual specific to your 1991 Ford Explorer is highly recommended. It will have diagrams, torque specifications, and detailed instructions. This is invaluable for this type of repair.
* Professional Help: If you're uncomfortable with any part of this process, consider taking it to a mechanic. Improperly installed hinges can lead to door problems and safety concerns.
Remember to take your time, be patient, and work carefully. Replacing door hinges is a moderately advanced repair. If you're unsure about any step, seek professional assistance.
