[455firebird1969]

My 2000 Formula drivers door has been out of alignment and getting harder to close. I went to NAPA and ordered a door hinge kit. The NAPA-solutions 600-5551 kit was made in China. The job took me about four hours to complete, see my list of required steps below.

1- drive front wheels onto ramps, level rear of car with jack stands under rear axle
2- support drivers lower control arm on a wood block (car still level) remove front wheel
3- remove inner fender liner, three screws, two bolts and three plastic push-retainers
4-remove upper hinge first, it's difficult to reach, but a 13 mm wrench works OK
5-grind OEM swaged end off of the two axle pins and drive pins out with a drift and hammer
6-assemble hinge with new bushings, axle pin/bolts and nuts, I added a SS flat washer in gap
7-reinstall upper hinge, I had my kid push-in the foreword upper end as I torqued hardware
8-remove lower hinge, it's easy to get to this one
9- grind OEM swaged ends and drive old pins out using a drift and hammer
10- reassemble lower hinge with new bushings axle pin/bolts and nuts, I added a SS flat washer
11- reinstall lower hinge and check door operation and alignment, adjust as necessary.
12-reinstall inner fender liner using old screws and new push-retainers ($3 each from GM)
13-reinstall drivers side front wheel and test drive

Note: I conducted the test drive prior to reinstalling inner fender to assure no wind noise from window/door misalignment. This way I could make fine tuning adjustments without having to remove the fender liner again.

I added a stainless steel flat washer (two different thickness's) to each hinge because I didn't like the gap after installing the new parts. I suspect the made in china bushings were not to specification. Either way, I shimmed them to my liking, and I greased everything during assembly.

The car was sitting on its suspension as normal during this process to prevent body flex that would misalign the doors.