The
first step is removing the door panel. Watch the speakers, a
screw driver will pop off the covers. There are screws along
the bottom of the panel, the door handle cover on the inside will also
need to be pulled off.
Gently
pull off the plstic screw with some needle nose pliers.
Moving to the exposed section of the hinge, you'll need to pull the
rubber boot off.
Once
you've moved the boot to the side, you'll see that the hinge is held on
to the A-pillar by a large torx screw. It should take some effort to
remove it. An extension is needed to clear the door.
The
hinge is held onto the door by two 10 mm nuts on the studs of the
hinge. The studs go through the door, only the nuts are exposed. Remove
those completely.
The
panel on the door pops off by pushing up on it. You won't set off any
airbags or break anything by pushing it off the door if all screws have
been removed. You should then see this:
That's
the front section of your door, with the hinge cover and the wiring
harness clipped onto it. Pop the white cover off and move the harness
to the side. To pull the hinge out, you'll have to rotate it
90 degrees, the end
section that bolts onto the A-pillar does not clear the hole in its
normal position. Below are the two hinges, top one being the
$35 replacement from FCP Groton. It's an OEM part, in a Volvo bag.
The
bottom part of the hinge is broken. It's hard to see on the previous
pics, but the studs kept the hinge against the door and forced the two
broken parts to grind and clunk. Next, you'll have to fit the
hinge back in the door. Again, maneuver it into the hole at a 90 degree
angle. Remember to put the rubber boot back on first, or
you'll be looking at this.
Once
you're done, you should have this result, a nice improvement.
Before you call it a day do not forget to apply some all
purpose grease to the newly installed hinge.
