Doors - removal and refitting
1 Open the door fully and support its lower edge on a jack or blocks covered with a pad of rag.
2 Three different types of hinge pins have been used in production
Door hinge roll pin
Door hinge solid pin (permanent)
Upper door hinge solid pin (removable)
and the particular method of removal for each type is given in the following paragraphs:
Roll pins
3 Detach and remove the plastic plugs from the hinge pins.
4 Using a suitable length of rod or, if available, Ford special tool 41.002, drift out the hinge pins: knocking them downwards. Get an assistant to support and steady the door during this operation.
Solid pins
Permanent
5 Where these pins are used, door removal is only possible after unbolting the hinges from the body. The fixing nuts can be reached after removing the side trim panel at the footwell and the facia panel lower cover.
Removable
6 This type of hinge pin can be removed after extracting the circlip and prising or tapping the pin downwards. The lower hinge pin cannot be removed and the hinge must be unbolted.
Both types
7 Lift the door clear of the stubs and remove it.
8 Refit the door reversing the removal procedure. Lubricate the hinges and pins as they are fitted and ensure that the hinge pin holes are correctly aligned when drifting the new hinge pins into position.