Derlin hinge bushings fit so tight the doors are hard to get back on

Lola · Apr 1, 2020

Hey guys, I had a quick question for y'all.

I recently replaced the stock door bushings with the Delrin replacements. Some of them fit too tight, to the extent that I cannot fit the door back on, and others fit too loose that they will come off as I take off the door.

Has this happened to anyone else? How can I go about fixing these?

Thanks all.

AndyG · Apr 1, 2020

Lola said:
Hey guys, I had a quick question for y'all.

I recently replaced the stock door bushings with the Delrin replacements. Some of them fit too tight, to the extent that I cannot fit the door back on, and others fit too loose that they will come off as I take off the door.

Has this happened to anyone else? How can I go about fixing these?

Thanks all.

Try swapping them around , see if that helps.

Scoutmapper · Apr 1, 2020

I recently replaced mine and didn't run into any looseness problems but did have a heck of a time getting some out. I sanded the inside down with a strip of Scotchbrite pad to get it clean and lithium greased it. The new ones slid in smooth with a suction sound. they were perfect fits. I had some paint issues on the hinges I cleaned up while doing this.

ballpark · Apr 2, 2020

Where did you buy the inserts?

Blanquito · Apr 2, 2020

Mine went in pretty good. Some were tighter than others, but not enough to trigger my OCD! Did you get the correct inserts, I believe they are different according to year, possibly even in the TJ models. I don’t have the instructions to check it. Also, the stock inserts are kind of a two piece unit. Seems to be a “fiber” insert inside of a metal insert. Make sure you get the metal out as well.
Hope that helps...

Fouledplugs · Apr 2, 2020

ballpark said:
Where did you buy the inserts?

They can be purchased from Quadratec as well as other online vendors.

ballpark · Apr 2, 2020

Fouledplugs said:
They can be purchased from Quadratec as well as other online vendors.

I was asking to see if he purchased the Quadratec ones or a knockoff... The quadratec ones were great for me.

Fouledplugs · Apr 2, 2020

ballpark said:
I was asking to see if he purchased the Quadratec ones or a knockoff... The quadratec ones were great for me.

Opps. Hopefully he replies, that would be helpful.

Blanquito · Apr 2, 2020

Got them from Quadratec.

ballpark · Apr 2, 2020

76CJQuadratrac said:
Got them from Quadratec.

I'd say my issue was too tight due to corrosion. I had to take the wire brush and put it in a drill to clean out enough crap to fit the bushing in. On the ones that are too loose, I would use some sort of adhesive to keep it in, and sand / clean up the posts on the door if that fit is too tight causing difficult removal.

Scoutmapper · Apr 2, 2020

ballpark said:
Where did you buy the inserts?

here: https://www.amazon.com/gp/product/B07813YKVY/?tag=wranglerorg-20

Goatman · Apr 2, 2020

Use a gun cleaning bore brush with a short extension and chuck it in your drill. Run that up and down through the hinge holes to get them cleaned out good. Then reinstall the new bushings. Put the tight ones in the loose holes and vice versa.

Lola · Apr 2, 2020

ballpark said:
Where did you buy the inserts?

I got them from Quadratec! I am certain I got the ones for my year (99)

Lola · Apr 2, 2020

Fouledplugs said:
Opps. Hopefully he replies, that would be helpful.

They came from Quadratec!

B34C0N · Apr 2, 2020

Lola said:
I got them from Quadratec! I am certain I got the ones for my year (99)

Did your original inserts go all the way through the hinge? Mine didn't go the whole way in and had to be cut short (97 hinges have bushings only halfway through)
I got mine a long time ago from TMR customs. I also had to clean the inside some before I pressed the new bushings in after getting the old one out.

Lola · Apr 2, 2020

LittleTankTJ said:
Did your original inserts go all the way through the hinge? Mine didn't go the whole way in and had to be cut short (97 hinges have bushings only halfway through)
I got mine a long time ago from TMR customs. I also had to clean the inside some before I pressed the new bushings in after getting the old one out.

The replacements that I received were already cut short!

Goatman · Apr 3, 2020

Using a C-clamp or a ball joint tool can help get them pressed in, just be certain all is lined up and clean. Then a slight dab of grease or spray can lube to help them slide home.

fourpointzero · Apr 5, 2020

Had to chime in and say, my stock one’s were a HUGE pain in the a## to remove, holy hell. I only got the driver side inserts replaced and bailed on the passenger one’s till Im ready to deal.

New inserts look great. In the process, I slightly kinked one of my hinges slamming it so hard with a hammer. Now, that door doesn't close as beautifully as it used to. The one below, I drilled out. Live and learn, I guess.

Goatman · Apr 6, 2020

Try using the hammer from the other direction. You should be able to pop the hinge back.

Captain Phoenix · Jun 2, 2020

ballpark said:
I was asking to see if he purchased the Quadratec ones or a knockoff... The quadratec ones were great for me.

I'm pretty sure the ones from Quadratec are knockoffs.

Derlin hinge bushings fit so tight the doors are hard to get back on

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