Removing side barn door hinge pins on GM van?

[zuren]

Has anyone had rusted hinge pins on their mid-2000s GM van and used this product (no affiliation with Double Arrow):

https://www.ebay.com/itm/automotive...m=R40&rt=nc&_trksid=m570.l1313&LH_TitleDesc=0


I have the 60/40 barn doors on both sides of my van, and I've struggled with the "40" doors since the day I bought it. The pins are severely rusted, to the point that I try to not use those doors and have to constantly tell anyone getting into or out of the van to not open those doors. I had seen this guy's tool for other GM models but the vans had recessed hinges and his solution wouldn't work. Looks like he came up with a new design.

When I called a body shop years ago, they wanted to charge $1000/side to fix my hinges. For $70, it may be worth the risk to try it. I already have the replacement, stainless, greaseable pins to drop in.

Thanks!

 

[Buliwyf]

I just hammered them out after a week of oil.

Tape some rubber to the body and use a punch.

 

[zuren]

I just hammered them out after a week of oil.

Tape some rubber to the body and use a punch.

Tried that. Taped a piece of 1/4" plywood to the van with a cutout for the hinge, after a few days of PB Blaster, and beat with a punch and small sledge hammer. Did not budge.

 

[Choff]

I Did it to my door pins, what a ********** !!! what worked is a lot of oil , big hammer and a drive pin to ********** the pins, tape cardboard or rubber to door for protection.

 

[Choff]

Be patient they don't come out easy !!

 

[FlipperFla]

Tried that. Taped a piece of 1/4" plywood to the van with a cutout for the hinge, after a few days of PB Blaster, and beat with a punch and small sledge hammer. Did not budge.

PB Blaster didnt do the trick? DAMN! Looks like that tool might be the last resort, sure beats $1000

 

[zuren]

...what worked is a lot of oil...

What oil did you use? I have PB Blaster but am reading online that Kroil is supposedly much better, but not sure where to buy it.

 

[tk3]

Buy direct from Kano Labs! Two 13oz cans for $14 plus shipping.
http://www.kanolabs.com/google/


Sent from my P00I using Tapatalk

 

[Herbie]

If they're anything like the door pins on the rear of Astro/Safari vans, they're splined and expand into the hole as they're driven home. And that make's 'em a ********** to get out.

Here's a photo of a similar pin (same diameter as the Astro OEM, but longer overall, with a slightly shorter splined section):

When I did the door rack on my driver's side (the first time around), I was able to drive the pins out by using a large socket on the top, and a small socket to push up on the pin, squeezed by a C-clamp (with a cheater-tube on the arm of the c-clamp):

The second time I tried this, I *bent* a couple of C-clamps before the pin came loose, so I used the parts from a different door-pin removal tool to build a tool specifically for the Astro:

Hard to see, due to the lighting, but here are the details:
The bolt on the bottom end is center-drilled to accept a set of hardened steel pins at the end. They're graduated in size, so you start with the short one, and substitute longer ones as you go.
The top plate has a hole large enough to accommodate the head of the door pin. Driving the bolt with the ratchet forces the pin up.

In both cases, the pins let go with a very loud *bang* when I finally got them to release. They're very tight in there!

EDIT: This is the door pin removal tool I cannibalized parts from to build my own tool with. The jaw size isn't wide enough to slip over the Astro hinges (nor the Express, I think).

 

[Choff]

Great job Herbie on the removal, looks like the same new pins I put in my GMC Savana AWD-- it's not easy job!!
Main thing when you get the hard work done is to keep them hinges lubed

 

[zuren]

My first approach was the C-clamp with the socket trick. I just watched the C-clamp continue to flex with each turn so I backed it off and tried going at it with brute force. The problem with the Express/Savana side doors is the bottom hinge is recessed into the door, so you can't get a clamp in there unless it is specific to the space/job.

I think I'll be ordering some Kroil and that extractor. In the meantime, I'm going to get the process started with some PB Blaster.

These are the pins I have ready to be installed:

https://www.dormanproducts.com/p-74...0Hinge%20Pin%20and%20Bushing%20Kit&origin=YMM

Greasable!!!

 

[bejinscbr]

Not sure if you're aware, but they sell complete replacement hinges for the GM side doors at the dealer. I think it was around $70 per hinge the last time I did one. You drill out the spot welds, and then simply bolt them on. Obviously have to paint, but then it's all brand new.