[Pame]

I am in the process of replacing the door stays and adding the reinforcement kit to my ‘85 911. After I removed all of the trim pieces my next step is to remove the small “pin” that holds the door to the chassis.

Here is my problem: When I tap on the pin, either from the top or bottom, it doesn’t move, the only thing moving is the arm itself. I believe that the pin is rusted/frozen to the arm keeping it from coming out. I am afraid if I keep hitting it I could bust the weld on the door or bend the tab. Thoughts, suggestions…help!

[Mike W]

If it is rusted, PB Blaster (penetrating fluid) might work if you let it soak long enough.

[smdubovsky]

You need to support the tab when beating out the pin. Put a deep socket under the tab, and put a wood block/jackstand/whatever under the socket. Or just hold a large piece of steel under the socket to use as mass (sledgehammer head?). You might be able to fashion something like a c-clamp to help press it out once it starts moving.

[Pame]

Thanks for the quick responses guys. After I let the penetrating oil soak for a few hours I will try the deep socket/steel/hammer technique.

--Steve

[}{arlequin]

it helps if you have someone else help you position the doors 'just so' in order to remove some of the tension that's on the pin as well. if the door is open just 'by iself' in one position, there is some tension being generated. pull it inwards a bit to lessen it.

[hoophead]

I just replaced my door stay too, and added the reinforcement kit. Fortunately, my pin came right out - just grabbed the top and bottom of the pin with some BF channel locks, and whacked the pliers with a 3lb hammer. Came right out.

Once I was done installing everything, I found that the door stay rubbed against the edge of the outer reinforcement plate. I had to dremel a little bit of the inside of the new door stay away to get the rubbing to stop. It still seems to hang a little bit with the door halfway open, but at least the awful popping is gone. Would have dremeled the reinforcement kit instead, but I already had the whole door and panel reassembled. Hindsight .

[Pame]

Great news…the pin is out! Thanks for all the suggestions.

I soaked the pin overnight and then again today. A few hours later I used the method described in smdubovsky’s post. Drove pin flush with the bracket using a ball peen hammer and then completely out with a drift pin, the entire time supporting the bracket with a deep socket backed up with a block of wood. Be SURE to tape the door jam to prevent scratching!

[Jase007]

Good stuff Steve [put your 1st name in your signature].

Dorkenginuity!!!

[Noah]

Nice work! Can you post a pic of the reinforcement kit? I recently replaced the door stay (the old strap broke right in half one day), and now I have a massive cracking sound when I open and close the door. I think the stay was too stiff and I broke something.

[Pame]

Originally Posted by Noah

Nice work! Can you post a pic of the reinforcement kit? I recently replaced the door stay (the old strap broke right in half one day), and now I have a massive cracking sound when I open and close the door. I think the stay was too stiff and I broke something.

I'll post some pics of the kit tomorrow afternoon.