I have a major problem with my driver door and the pins. I had the pins replaced a while ago, but no one can get the door spring back in. I have just taken my truck for it's warrant and received a warning about the front door as it is now sagging. Looks like the top hole where the pins sits is not round any more but oval. Any ideas on how to fix this and how to get that dam spring back in???????

 

Asked and answered many times. You have three options; replace the hinge complete, weld up the oval shaped holes then ream them back out, or use some structural epoxy to support the bushing. I would weld up the hole and ream it back out to size.

As far as the spring goes, just get the proper tool. $15-$20 most places. It is a light truck door spring compressor.

 

It is not clear from your post if the oval is in the bronze bushing or in the hinge it's self. If it is just the bushing you can replace it. If it is the hinge, then depending how bad it is you may have to repair or replace the hinge as stated above.

A few drops of oil every 6 months and the bushings would probably last forever.