This installation guide is intended to be used to assist you during the installation of your JK Delrin® Door Hinge Bushing Kit from Bantam Overland.
These instructions are applicable for 2 Door and 4 Door 2007-2018 Jeep Wranglers.
Step 1:
Remove the Doors
- Wear safety glasses.
- Work on one door at a time — no rushing!
- Remove the two (2) T-50 Torx bolts securing the door to the hinge knuckles.
- Carefully disconnect the wiring harnesses and check straps.
- Open the door to about 90° — do not go beyond this angle to avoid damaging the door or vehicle body.
- Lift the door straight up and off the hinges while it’s held at 90°.
- Place the door on a soft, protected surface.
Step 2:
Clean the Door Hinge Pins
- Use the emery cloth from the kit to thoroughly clean both hinge pins.
- Wrap the cloth around the pin and use a back-and-forth motion to clean its full circumference.
- Avoid scuffing painted areas.
- Test-fit the bushing as you clean; each pin should take about a minute.
Step 3:
Test Fit the Bushings
- Slip a Delrin® bushing onto each cleaned pin.
- The bushing should slide on smoothly by hand without force.
- If it’s too tight, continue cleaning with the emery cloth.
Step 4:
Lubricate the Pins
- Once the pins are clean and bushings fit well, apply a thin coat of grease.
- Do not over-lubricate.
Step 5:
Remove the Old Bushings
- Insert the stepped end of the Bushing Removal Tool into the hinge from below.
- Tap it with a medium hammer to push the old bushing upward and out.
- For stubborn bushings, apply penetrating oil a day in advance.
Free a Stuck Tool (if needed)
- If the removal tool gets stuck, use a 5/16” deep socket (¼” drive) to tap it down and out.
- Do not tap upward.
Step 6:
Clean the Hinge Knuckle Interior
- Use a small, round fine-tooth file (e.g., a chainsaw file) to clean inside the knuckle.
- Work the file all around to remove buildup.
- The new bushing should slide in easily — debris will prevent proper fit.
Step 7:
Install New Delrin® Bushings
- Bushings should install by hand or with a light tap — do not force them in.
- If too tight, remove and file the knuckle further. Avoid over-filing to prevent a loose fit.
- After inserting the bushing, repeat Steps 2–7 for the second bushing.
Step 8:
Reinstall the Door
- Reinstall the door at about 90° to the body, taking care not to damage it.
- Reconnect wiring and check straps.
- Reattach the two (2) T-50 Torx bolts.
- Repeat Steps 1–8 for each door.