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post #1 of (permalink) Old 06-03-2009, 08:55 AM Thread Starter
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Windshield Hinge Question, drilling out pin.

My 91 YJ windshield hinge pins have been stuck (rusted) for at least 10 years. No visible rust on the surface. When I last tried to fold the windshield down the hinges started to bend.
I replaced the windshield frame 8 years ago and had to drill out the torx heads on the upper half of the hinges.
I would like to make the windshield fold but I don't want to drill out the lower hinge torx heads because I would have to remove the dash to install new bolts.

Has anyone drilled out the pins? Can I hammer them out with a punch?
I would like to put pins in there so that I could quickly remove or fold the windshield for trail rides. I should also get better mileage while towing it on the trailer if the windshield is folded.

I drive over things.
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post #2 of (permalink) Old 06-03-2009, 01:14 PM
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Here's what I would do; drill a hole in the middle of each hinge knuckle on the upper side. Go deep enough to drill slightly into the pin. Then dribble penetrating oil into the hole. I prefer Kroil but PB gets good reviews too. After a couple of days rap lightly on the knuckle with a hammer for a while. Eventually it will free up.

You could drill the holes #7, tap them 1/4-28 and screw a zerk in. A shot of grease every few months and they'll never rust again.

To remove the pin you'll have to grind the welds off the ends, but as long as it's rust-frozen in the middle you won't get the pin out. And the pin might be rust-frozen into the end knuckles, too. It could be a real project to get out. I prefer this approach. These are hood hinges I made, and I plan to make similar windshield and tailgate hinges when I have the time. Lift the hood about half way to align the flats on the pin with the slot in the knuckle, and it comes right out.

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post #3 of (permalink) Old 06-03-2009, 03:32 PM
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Quote:
Originally Posted by Jim_Lou View Post
Lift the hood about half way to align the flats on the pin with the slot in the knuckle, and it comes right out.

Attachment 75927
Just like the M38A1. The windshield hinges and hood hinges both are that way.

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post #4 of (permalink) Old 06-03-2009, 03:55 PM
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As were early CJ5s, which is where I got the idea. The passenger seat was also on similar hinges so it could be lifted out easily.

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post #5 of (permalink) Old 06-03-2009, 07:44 PM
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Jim has you headed in the right direction. You will have to get the hinges freed up and grind the welds out. After you get the pins out just get a bolt that fits where the hinge pin was and install helicoils for the bolt to thread into. It has been a while since I did mine so i don't remember the correct bolt size.

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post #6 of (permalink) Old 06-03-2009, 09:05 PM
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I had the same problem.

Mine wouldn't budge. So I pulled them, heated with a torch and got them free.

I knew it wouldn't last at this point so I ground the end of the pin , punched them out and replaced with a stainless one. (easiest thing for me as brass/bronze would have done the same but I had the stainless at my disposal)

I have seen a lot of different fixes in the same realm but thats how I did it.

Not a big deal. Repaint was the most work. (still no biggie on my crusty CJ)

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post #7 of (permalink) Old 06-03-2009, 10:48 PM
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Funny this thread should come up at this time.
I'm working over two sets this week as I get time to mess with them.

I'm drilling out and replacing with a type of locking pin so we can pull the hinge pins and remove the windshield.

I would do the milling machine bit, but pulling the factory hinges is a PAIN with the torx bolts rusted on like crazy!
Anyway, I figure brass pins with snap link closures to keep them in place will work just fine, and I have all that stuff around here.
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post #8 of (permalink) Old 06-04-2009, 12:08 PM Thread Starter
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I think I will give the PB thing a try this weekend then check for results next weekend.
Thanks.

I drive over things.
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post #9 of (permalink) Old 06-04-2009, 12:17 PM
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Dropping penetrant between the knuckles isn't likely to help, at least in your lifetime. Some hinges had oil holes from the factory. If yours don't, drill them yourself.

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post #10 of (permalink) Old 06-04-2009, 04:23 PM Thread Starter
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Yes, I plan on drilling the holes before adding the PB.

I drive over things.
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