Recently I replaced door hinge bushings and pins on both doors. (89 S15 Jimmy 2 DR, 2WD, Auto). The passenger side door opened and closed smoothly without any noise or binding. However, the drivers side was making a creaking noise every time the door opened or closed. Upon a closer inspection I noticed that the swing arm for the door spring had excess lateral movement causing the binding. The swing arm is not available anywhere as a replacement part. I did find a NOS Service Hinge Assy. on ebay that included the swing arm as part of the assy.

The service hinge came with instructions to remove and replace the complete hinge assy. on the door. I really did not want to get into all of that when all I needed was the swing arm. The swing arm was attached with a pin and a bushing that are welded together. It was pretty difficult removing the swing arm from the hinge assy. Once I drilled out the center of the bushing I was able to remove the swing arm and re-use the bushing. The bushing is 1/2 OD, 5/16 ID, about 3/8 tall. The swing arm has a 1/2 dia hole that rides on the bushing. The bushing itself when installed on the swing arm is slightly thicker than the swing arm. Instead of trying to replicate the OEM installation i opted to use a bolt and nut to secure the swing arm assy. on the vehicle.

I was able to use carbide bits to grind out the bushing flange on the vehicle and the old swing arm and top part of the retaining pin. I attached the new swing arm and bushing with a Stainless 5/16-18 Button Head bolt and a Stainless jam nut. The door operates smoothly with out any binding.

The first image is the completed installation. The second image is the service hinge assy. with the old swing arm in position.

 

Nice repair!

 

Thanks. The hard part was figuring out the best method to remove the swing arm from the bracket not knowing how it was put together. I thought it was a straight pin but did not know that the swing arm rotated on a 1/2 dia. flange bushing. that was mounted on the underside of the swingarm. The pin was a 5/16a" pin that went through the center of the bushing and was welded to the face of the bushing.

 

I was able to refurbish the original swing for use in the future. I was able to drill out the swing arm to accommodate a steel spacer. I silver brazed a 5/8" OD with 1/2" ID spacer. I installed a 1/2" OD & 5/16 ID bronze flange bushing in the swing arm and bolted it to the spare door hinge with 5/16-18" X 3/4" stainless pan head screw and a 5/16 X 18 Jam nut. I blasted and painted the door hinge and swing arm in black.