Section 01-03: Doors, Deck Lid and Liftgate
1993 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Door

 

Body Side Hinge Bolt

An extra length service bolt has been released to replace the production bolt in cases where the shim buildup thickness under the body-side hinge is sufficient to reduce thread engagement to an unacceptable level.



 

Hinge Pin

Tools Required:

Since the pivot pin for the upper hinge must be broken and removed in two pieces in order to clear the door hem flange, a special service replacement pin has been released for upside-down installation and hairpin clip retention.

 

Removal

  1. Remove trim panel, watershield and all usable outside mouldings and clips (if the door is to be replaced). Refer to Section 01-05.
  1. Remove wiring harness, actuator and radio speaker from the door, if so equipped.
  1. Remove all usable window and door latch components from the door (if the door is to be replaced). Refer to the appropriate Sections in this Group.
  1. Support the door using Rotunda Door Rack 103-00027 or equivalent for door service.
  1. Break the upper hinge pin in half using bolt cutter or similar tool (hammer and chisel, if necessary) for easier removal.
  1. Remove upper hinge pin pieces.
  1. Break the lower hinge pin in half, using bolt cutters or similar tool (hammer and chisel, if necessary).
  1. Remove lower hinge pin pieces.
  1. Separate the two hinge halves and remove door.



 

Installation

  1. Position door on vehicle, lining up hinge halves.
  1. Install the service hinge pin in the top hinge to secure the hinge halves together.

    NOTE: The top hinge pin is installed upside-down.

  1. Install the removed hinge pin for the lower hinge assembly.
  1. Drill holes as necessary for retaining the outside mouldings and hardware components.
  1. Install the wiring harness, actuator and radio speaker in the door, if so equipped.
  1. Install latch mechanism, window mechanism, glass and glass weatherstripping. Adjust the window mechanism.
  1. Install exterior mouldings, watershield and door trim panel. Refer to Section 01-05 and Group 01.
  1. Lubricate hinges with Multi-Purpose Grease Spray D7AZ-19584-AA (ESR-M1C159-A and ESB-M1C160-B) or equivalent.
  1. Check door alignment. If it requires outboard adjustment to be flush with the surrounding sheet metal, install a shim(s) under the body-side hinge halves.