Door Pin Fix
 

Door Spring Tool - GM Vehicles 87675 $15.25
Use to remove and install the door hinge springs found on late model General Motors vehicles. Makes a hard job easy. Can be used with 1/2" open end or ratcheting box wrench.
http://getmetools.com/pics/ss21910.jpg
http://www.mytoolstore.com/toolaid/87675-2.gif
Should your hinge pin holes be egged (taking on an egged shape) You have the option of either replacing the hinges ($400.00) or filling in the holes with weld, grind down, then redrill (about 20 mins worth of work) Fortunatly i didn't have to buy new ones
Tools needed:
BF Hammer
Punch or pin removal tool
Masking tape
Lithium grease
Door Spring tool
a friend to help or a jack with a door cradle
Hinge pins and bushings
So we start by taping up the inside and outside of the door to prevent damage to the paint
Next you remove the door spring
Now the door needs to be supported. Here's where the jack and door cradle came in handy as well as the extra set of hands. These doors are heavy and awkward, so having a friend balance the door makes life a lot easier. Optionally if you can build or buy yourself a proper door cradle, a buddy won't be needed for anything except passing you a tool or two

Most people think it's simple to knock pins out. It's not. First you need to make sure you don't whack the windshield or car, secondly, they can be in there pretty tight. Some pins can be rusted to hell and it can really take a lot of persuasion. 2 long 1/4" ratchet extentions will work. I find this better than a punch because the hole in the base gets a nice lock on the top of the pin. but you can buy the pin removal punch to make life a little easy This will prevent it from shifting as you're whacking it and you won't put any dents/dings into your body.. Also, you may have a little ring on top of the old pins. Don't worry about it, they can't be reused. As you punch the old pin out, it will fall off.
DOOR HINGE PIN REMOVAL TOOL KIT
http://www.sulco.co.nz/products/598/...ll/3201575.jpg
I have this one
http://getmetools.com/pics/ss21835.jpg
• Removes door hinge pins FAST
• Drives out even stubborn hinge pins
• Direct impact
• Clearance for door panels
• Works on all GM cars with removable hinge pins
• Includes PIN PULLER to remove loosened pins
Door Hinge Pin Popper: $18.93
i would also buy this tool if i was you it makes life easy
E-Z Store Door Alignment Tool: $19.07
Saves space. Fits easily into your tool drawer. No long, heavy bar to store!
• Uses your breaker bar for leverage.
• Save time. You won't have to hunt for the shop tool.
http://getmetools.com/pics/ss21845.jpg
Next seperate the door from the body..Do this slowly to prevent paint/metal damage to your car
take our large flathead screwdriver and put it against the bottom of the old bushing and whack it with the hammer. Depending how tight your old bushings are, they can either immediately fall out, or you will have to chip away at them until they fall out. If they fall out without anyforce, take a good look at the bushing hole to check for egging. Once the bushings are knocked out, you will be left with this..(Now is a good time to take a brush and maybe soap and water and clean any debris in the holes and surrounding dirt off the door jam and hinges
Now for the installation of the new bushings
If you want, you can now tap in your new bushings with a hammer. The problem with this is that you run the risk of damaging the bushing, especially if it's an OEM bushing and not a splined aftermarket. So what would would any self respecting car guy do? Improvise! you can created a nice press out of some stuff in your shop.
The press can consisted of a 2-1/2" bolt that would fit through both bushings, a washer, a socket, and a 13mm nut.This made life a lot easier and take about 10 seconds to do. Simply tighten it down until the top of the bushing meets the hinge.
When you get all 4 bushings done, simply load the door back onto the hinges, and slide the pins in. Once they are slid in, take your punch tool
and hammer the pins all the way in. You will have some clips with the new pins, these need to go on! Simply press them on top of the pins down to the hinge metal. Reinstall your tension spring and check the door for looseness by lifting it up and down. You should have no play what so ever. Check your door that it closes right. Spray the entire area including the spring with lithium grease. You may hear some creaking but it goes away after a bit once the grease has worked itself in. If out of alinement use the tool i posted above

Those are some handy tools Tony. I know some members will be needing them in the future.