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| stevegsmith Expert Date registered: Apr 2006 Location: SF Bay Area, CA USA Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99 Posts: 1301  | ||
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | ||
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| stevegsmith Expert Date registered: Apr 2006 Location: SF Bay Area, CA USA Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99 Posts: 1301 | ||
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| RE: year of door hinge change hi steve . the old type W460 sll have welded hinges . the newer W463 models got bolted hinges on the doors as the hinges are always worn depending on the high weight . see attached a photo of a 1995 W461 290GD worker . this G is similar to the W460 as it still has the W460 axles and transfer case . the german army wolfs have bolted doors , so it started 1990 or earlier . it seems your old G got new doors one day . if you need new hinges on your old doors you will have to use W463 hinges now and they must be welded exactly , if you have bolted ones the W463 hinges will fit . mfg. guido . (1995 worker.JPG) Attachments ----------------  1995 worker.JPG (146KB - 5 downloads) | ||
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| stevegsmith Expert Date registered: Apr 2006 Location: SF Bay Area, CA USA Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99 Posts: 1301 | ||
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| RE: year of door hinge change hi steve . attached pics of the bolted hinges from the worker . if you use this kind of hinge you can weld it into your door . i never tried to put out the pin . it is not a good idea as it will always run out in future . i see only the way to remove the old one and fix in a new one  mfg. guido . (top hinge.JPG) (bottom hinge.JPG) Attachments ---------------- top hinge.JPG (80KB - 2 downloads) bottom hinge.JPG (82KB - 3 downloads) | ||
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| Titus Pullo Elite Veteran Date registered: May 2007 Location: Ottawa, ON, Canada Vehicle(s): '90 Wolf 240GD, '06 G270 CDI. Posts: 1010 | ||
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | ||
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| Inkblotz Expert Date registered: Apr 2006 Location: Georgia Vehicle(s): 90 300GD "Thundering Turtle II", w/ 603A turbo Posts: 3186  | ||
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| stevegsmith Expert Date registered: Apr 2006 Location: SF Bay Area, CA USA Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99 Posts: 1301 | ||
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: year of door hinge change As it also is described on Hans Hehl's site, I'm converting my 'welded' hinges, to bolt on hinges. As my door hinges are worn of rusted, it's a good time to replace them with new bolt on hinges. The top hinge already got two large holes, to insert an allen M6 bolt which bolts on the door hanger. The lower hinge doesn't have any holes. However, if you look at the inside of the door (remove inner door panel), there are two 6mm holes on the door frame to which the lower door hinge is welded on. Use a drill with a 6mm drill bit, and drill through this 6mm hole and through the door hinge. When this hole is drilled through, drill it to 8mm from the top. Next you can remove the welded door hinge. Using a template and already the two 8mm holes, drill the other two holes. Do the same on the top hinge. Aready the first pics. Drilled 6mm from inside, then 8mm from outside:  ] Bolt on door hinge:  ] Same procedure for top hinges this already got the 6mm holes. Drill them to 8mm.  ] More info and pics will follow soon for the rest of the steps. gr Bram | |
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: year of door hinge change Using the bolt on door hinge I already got, I made a template for drilling the other holes in the door. The holes in the bolt on door hinge are 9mm, so using the 9mm drill, I 'centered' 4 points in the template using the hinge as a guide. I drilled two of these points to 8mm, the other 2 to 3mm:  ] After deburring, here's what I got:  ] Using two 8mm drill bits, I can fairly accurate line up this template with the 8mm holes already in the door:  ] Using a centerpoint which just goes through the 3mm template holes, I marked the other two holes:  ] Drilled a 3mm bit through these marked points, basicly all the dimensions for the bolt on hinge are now copied on this welded door hinge and door:  ] Of course do the same on the top door hinge:  ] Time to start cutting. Using an angle grinder and a Dremel, cut the weld on about a 45 degree angle. Pretty big welds, make sure you cut deep enough:  ] Using a chisel or something, tap the hinge loose if the welds a sufficiently cut through. Be careful not to damage the door if the welds are still too strong:  ] This is a picture from inside the door. Here you can see the reinforcement beam that already has two 6mm holes which I used in the first steps:  ] And here's the result of very rusty, stuck door hinges. The door starts cracking, because of the strain put on there by the door hinge. Will need to cut that out and weld again.  ]  ] Next steps is to grind away the remaining welds. Drill the 3mm holes to 9mm, so using 9mm drill bits, the new hinge can be lined up on the right spot. Then bolt on the hinge using the M8 bolts in the other two holes. If these are tight, remove the drill bits and insert the next two M8 bolts in these holes. If you're keeping the old door hanger, these mounting holes also need to be enlarged to suit the M8 bolts. Gr. Bram | |
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | ||
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hipine Date registered: Jul 2006 Location: US, CO, Bailey Vehicle(s): 460 1980 280GE w. 617A  | Re: year of door hinge change Nice work Bram! Thanks for sharing. This is good incentive to keep those hinges well lubricated!!! All the best, -Dave G. PS - right now I'm waiting for some hinges to arrive....from Norway.... not for the G, but for the dust cover for a Micro Seiki BL-91 turntable I acquired from a friend recently. It seems I enjoy lots of things that are labors of love contributed to by friends across the globe. What a blessing. | |
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | ||
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: year of door hinge change When your hinge is rusted and rotating very hard or is worn out and having way too much play, you can rebuild your door hinge. As these hinges are pretty expensive parts of which you'll need multiple ones per car, I decided to give repairing a try, instead of buying new ones. Some pics showing the disassembly, repair info will follow later: Using a shop press, I managed to press out the door pin from the hinge (about 5 ton of force)  ] The doorpin severely rusted away:  ] The doorpin is locked in place on the upper and lower part of the door hinge. The middle section of the hinge rotates around the door pin. For this, bushings are installed in this middle section:  ]  ] Sometimes, these bushings have completely disappeared after many years of rust, vibration and wear. Then the hinge will show lots of play. I will clean up the hole in this middle section, install new bushings and install a new doorpin, should be good for many years of door-opening and closing operations. Will update soon. | |
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| bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: year of door hinge change Here some pics of some hinges I fixed many years ago. Have to find what type and brand of bushings I used at the time...  ]  ] gr. Bram | |
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| Atl-Wagen Member Date registered: Sep 2014 Location: Atlanta, Georgia Vehicle(s): 80's something w460-230ge 2013 Honda Ridgeline Posts: 47  | ||
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