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You guys were a big help to me on my last problem. Maybe this time you can give me some advice. I went to change out the wiring harnesses that route through the tailgate hinges today on my wife's 92 240 S/W. Not a problem because I have the new harnesses and I done it once before on my daughter's '93 240 S/W. (We have three 240 S/Ws (2)-'92s and the '93. I love 240s!) All is well until I unbolt the driver's side hinge from the tailgate. The long 'tab' that fastens the hinge to the tailgate (with the Torx head bolt) has broken off. Apparently it has been broken for awhile but the hinge has held even through all the tailgate slamming the wife can do.
I don't want to spend a whole lot of money replacing these hinges so my first thought was to see if one of my collegues at work can braze the tab back on the hinge. But as I examined both the driver side and the passenger side hinges I noticed that they both have a lot of play where the hinge pin holds the two halves of each hinge together. It looks like the bushing on one is gone for the most part. Now I'm thinking well I'll have the tab brazed back on and I'll have some bronze bushing turned to fit and the hinges will be better than original.
But I can't get the two halves apart. I removed a small pin that locks the hinge pin in place but it looks like the hinge pin was driven in with the intent of it never being removed. If this is so these hinges are ready for the scrap heap. I hate throwing stuff like this away. Anyone got a method to remove the hinge pin? Should I drill and tap a small hole on the exposed side, put in a cap screw and try to pull the pins out? Anyone ever tried this?
Am I the only cheapskate at brickboard.com? :)
And barring the repair of these, who sells the best replacement hinges. These are black but I like the crome ones fine.
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