by vwlimoguy » Wed May 23, 2012 3:25 pm
There are three places it could come loose. The easiest to fix would be the big #4 Phillps screws that go into the A pillar; that ones you take out to remove the door. Less fun would be the spot welds where the hinge attaches to the door. These sometimes crack and need rewelded. The most difficult thing (imo) to fix is a worn out hinge pin and barrel. They make oversized door pins, but the barrel is usually ovaled out and they don't fit perfectly. Getting the old pin out is difficult because you have to press it out and there's this big door thing getting in the way. Someone makes a C-clamp looking thing for this job, but its spendy. I drilled out the barrel of the hinge to a greater oversize, then pressed in bronze bearings which I then reamed out to fit a standard diameter door hinge. Super overkill for a car that has been in the rain only once since then.