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Nurburgringer - This is all I've ever found outside of cutting off the hinge with the rollers and welding a functioning one on:
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Grand Cherokee Problems - CarSpace Automotive Forums
cheap & easy fix for door hinge rollers by wol May 20, 2003 (9:01 am)
The front door hinges on my '97 GCV8 have two little capstan rollers that click past the detent spring. (This is to hold the doors open on inclines) In spite of regular maintenance, these rollers get stiff and creaky.
Recently, one of the rollers shattered when I opened the door, scattering small ball-bearings. The sharp edge of the capstan post soon began to cut into the detent spring and made an 'orrible grating noise on opening the door.
I figured that it was time to fit a new hinge, but Jeep hinges are welded on the door side and bolted only onto the frame side. The rollers are on the door side, making a weld inevitable. The dealer told me that it might cost hundreds to fix. The hinge is only $50, but there is cutting, welding and repainting. (And inevitably, rusting!)
The fix is to go down to the hardware store and buy a "nylon spacer" that is about the same outside diameter as the original roller. 59 cents in Home Depot.
Before starting, check the hinge detente spring. If it is badly chewed up, this fix might not work for you. If it is just a little chewed up, use a fine file or abrasive to ease off any burrs.
Using a drill or dremel with a conical grinding (or abrasive head) ream out the inside diameter of the spacer from both sides until it _just_ sits on the head of the capstan post.
By using a conical grinding head, you'll leave a slight bulge inside the nylon spacer which is a tad smaller than the diameter of the capstan.
(The inside has an hourglass shape.)
Grease the capstan post and sit the nylon roller on the top.
Give the roller one sharp rap with a hard plastic mallet or dead-blow hammer. The roller should pop permanently onto the post. If it doesn't, clean it up and ream it out a bit more, but not so much that it won't stay on the post.
If you get the inside diameter of the roller just right, it should rotate freely but stay on the post. Even if it doesn't rotate freely, it won't matter (read on).
Grease the hinge well with an appropriate hinge lube. I use a grey high-flashpoint lithium grease which seems to hold the creaking at bay between services.
The resulting roller works perfectly and is actually quieter than the original. If it doesn't rotate, it just wears down slightly where it contacts the spring, and you might have to replace it again later. It won't damage or abrade the spring. Mine has lasted well for 8 months.
It's important to pick a spacer made of the hard, slick nylon that is typically used as an axle spacer on small cart axles. That kind of plastic is self-lubricating and hard wearing. They come in a variety of diameters and lengths - i didn't need to cut it for length.
I hope this tip helps someone else save a few bucks on hinge work.
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Door Hinge Pin Replacement
