Rear hatch hinge troubles.

[IdubThee]

So I need to replace this mangled hinge in order for the rear hatch to close correctly. I found and bought a replacement online (just the lower piece that attaches to door). From what I have read on here so far, sounds like a nightmare job trying to take out the cross bar in order to replace. I figure, can't i just remove pins connecting the lower portion of hinge to upper, therefore bypassing the need to remove the whole assembly by way of cross bar maneuver? I'm stuck on getting these pins out though. Any tips, tricks, thoughts?

[Mike Fisher]

http://home.clara.net/hallvw/technical/tailgate.htm is a Factory document/how to tackle this operation. You have to bend up a heavy screwdriver or brake spoon etc to use for the levering involved.
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https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold

Society is like stew. If you don't keep it stirred up you end up with a lot of scum on the top! - Russ_Wolfe/Edward Abbey

[IdubThee]

So there is no way to get around taking the torsion rod out?
Looks like someone finally made a video of procedure on youtube:



Link
[/youtube]

[ddare]

I tackled this job once. It was pretty hairy. I replaced just the lower hinge, which did require tensioning/removing the torsion bar. Within a couple months the 'new' lower hinge developed the same problem -- when the hatch would fully open, the hinge would travel too far and bind up, and I would have to bite onto the hinge with channel locks and pull down in order to close the hatch. I never resolved it as the headliner was new and I didn't want to tear into it to get to the lower part of the hinge, as I recall.

[Mike Fisher]

The round holes will get oval and have to be replaced for the hatch to ever work properly.
_________________
https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold

Society is like stew. If you don't keep it stirred up you end up with a lot of scum on the top! - Russ_Wolfe/Edward Abbey

[nogoodwithusernames]

[IdubThee]

Looks like this is the piece that we are talking about here with the worn pin hole. Any ideas on rehabbing this one, or should I look to fabricate one from scratch? Keep in mind my machining skills are limited and I'm kind of looking for quick fix.

[sqbk1971]

Can you find/make a metal bushing with the right ID and OD that you would need?

I am sure you would have to be careful about your center point, but its an idea for quick fix on a non-critical area of the car.

[nogoodwithusernames]

[Bobnotch]

Another option would be posting up a WTB (Want To Buy) ad in the Classifieds.
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Bob 65 Notch S with Sunroof
71 Notch ...aka Krunchy; build pics here;
http://www.thesamba.com/vw/forum/viewtopic.php?t=249390 -been busy working
64 T-34 Ghia...aka Wolfie, under construction... http://www.thesamba.com/vw/forum/viewtopic.php?t=412120

[IdubThee]

I settled on JB welding a bushing into the worn hole on the upper portion of the hinge piece ("b" side). But I can't for the life of me get the hole to line up enough to get both pins back in. This picture is with the "a" side pin in and the "b" hole not lining up. I assume this means some other portion of the assembly is slightly off. Does making a new piece and drilling to fit the current positioning make sense at this point for a temporary fix, enough to get the door closed at least? I don't know how to weld or have any gear to do so, otherwise I guess I could close up the holes on existing piece and re-drill.

Wisdoms are much obliged.

[nogoodwithusernames]

Looks like you need to twist the torsion bars a bit so that hinge isn't under pressure. You can use a screwdriver or something, I've got a brake adjusting tool that works really well.

If you really just need a temporary fix why not just get a dowel or broomstick to prop up the hatch and only use the big bent hinge piece (the one that actually holds the hatch) until you can get the new hinges?
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71 Squareback, 1.7l T4 w/ crank trigger fuel and spark
(Conversion thread https://www.thesamba.com/vw/forum/viewtopic.php?t=732508&highlight= or https://shoptalkforums.com/viewtopic.php?f=1&t=151375&sid=f0542d44a322d290c29d6609fac7f215 )
74 914, 2.0L w/ D-Jet

-Derek