my drivers side door had an annoying, loud click at the hinge - inspection revealed that the roller bushing was very worn with deep ruts. looks like at some point the roller froze and scraped against the hinge detents, causing little furrows that then increased over time.

was inspired by another post about re-building door hinges and decided to take the plunge and pull off the door to fix it.

taking off the door is simple, but most definitely a two-person job. 6 bolts and its off. then i took the lower hinge off the car, put it in my vice and tapped out the roller pin. the previous post about hinge re-building had a replacement part number from mcmaster-carr and they were perfect fit. compressed the spring against the hinge arm in the vice and tapped the pin back in, couple of squirts of paint on the back of the hinge and the door was back on in less than an hour.

and NO MORE CLICK!!

pic is new roller vs. old and the part info.

Fantastic! This is good because I opened the passenger door yesterday and I hear this awful sound coming from the hinge. Long story short-I too have the same thing happening with the bushing. Going to order a couple.

Good to know. McMaster-Carr to the rescue again!

I used a bronze bushing which I cut to size and used on the drivers door, worked great with no click for about 3 months and now the click is back. I think my hinge part with the detents is toast.

bronze can be pretty soft - depending on the alloy, and the spring puts quite a bit of force on the detents. perhaps your bushings have already begun to get those clickety divets again...