Door Hinge

This procedure covers removal and installation of door hinges on the 1992 Dodge Viper, including door removal, hinge replacement, and alignment verification.

Warnings

Tools required

Parts

• Door hinge (upper or lower as needed) × 1 — Use OEM specification
• Door hinge pin and bushings (if servicing existing hinge) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable to disable power door locks and prevent accidental window operation
3. Open door to be serviced and position door support stand or have helper ready to support door weight
4. Apply masking tape to fender edge and door edge near hinge area to protect paint
5. If working on door-mounted electrical components, disconnect door wiring harness at body junction connector

Procedure

1. 1

   Mark hinge positions
   Use a felt-tip marker or paint pen to mark the exact position of each door hinge on the door and body pillar (verify hinge count and configuration against factory service documentation). Draw alignment marks across the hinge-to-door junction and hinge-to-body junction. These reference marks are critical for proper door alignment during reinstallation.
2. 2

   Disconnect door wiring harness
   The first-generation Dodge Viper RT/10 has minimal door electrical content (no power windows or power locks). If any wiring is present in the door (e.g., for optional components), locate the connector in the body pillar, press the release tab, and disconnect the harness, pulling sufficient slack into the door cavity to allow door removal without damaging wiring. Otherwise, proceed to the next step.
3. 3

   Support door weight
   Position a padded floor jack under the door edge or use a dedicated door support stand beneath the door. Adjust height so the door is supported at its natural position with hinges unloaded. If using a helper, have them firmly grip the door at the outside edge with hands positioned to control both weight and swing.
4. 4

   Remove door-to-hinge fasteners
   Remove the door hinge bolts securing the hinges to the door (verify bolt count per hinge against factory service documentation). Note how the bolts engage the door frame. Support the door firmly while removing the final bolts to prevent sudden drop or swing. Support the door firmly while removing the final bolts to prevent sudden drop or swing.
5. 5

   Remove door from vehicle
   With all door-to-hinge fasteners removed, carefully lift the door straight up and away from the hinges. Guide the door forward to clear the body opening. Set the door on a padded surface with the outer panel facing up to prevent paint damage. Do not rest door on its edge unsupported.
6. 6

   Remove hinge-to-body fasteners
   With the door removed, remove the hinge-to-body pillar bolts. Verify the number of bolts per hinge securing each hinge to the body pillar against factory service documentation before removal. Note the position of any shims between the hinge and body pillar, as these control door alignment. Keep shims organized by hinge position (upper/lower) for reinstallation.
7. 7

   Remove hinge from body
   Remove the hinge assembly from the body pillar. Inspect the hinge for worn pins, damaged bushings, or cracked mounting flanges. Check body pillar mounting surfaces for damage or elongated bolt holes that would prevent proper alignment.
8. 8

   Inspect and prepare replacement hinge
   If installing a new hinge, verify it matches the original (upper or lower position). Check that hinge pins move smoothly through their arc with appropriate resistance. If servicing an existing hinge with new pins and bushings, press out old pins, replace bushings, and install new pins per hinge rebuild specifications. Apply a thin coat of multi-purpose grease to hinge pin contact surfaces.
9. 9

   Install hinge to body
   Position the hinge assembly on the body pillar, aligning it with the reference marks made during removal. Install any shims that were originally present between the hinge and body pillar in their original positions. Start all hinge-to-body bolts by hand to ensure threads engage properly, then torque in a cross pattern to specification.
10. 10

    Install door to hinges
    With helper or door support stand, position the door at the body opening and align the door hinge mounting flanges with the hinges on the body pillar. Use the reference marks made during removal to achieve approximate alignment. Start all door-to-hinge bolts by hand before tightening any. Once all bolts are started, torque in a cross pattern (alternating upper and lower hinge) to specification.
11. 11

    Check door alignment and operation
    Open and close the door several times to verify smooth operation through full range of motion. Check door-to-body panel gaps at front edge, top edge, and bottom edge for uniformity. Door should be flush with adjacent body panels when closed. Check door seal contact around entire perimeter. If adjustment is needed, loosen hinge-to-body bolts slightly and shift door position, then retorque.
12. 12

    Reconnect wiring and finalize
    Reconnect the door wiring harness at the body pillar connector. Verify connector locks fully. Test any door-mounted electrical components if equipped (note the base Viper RT/10 does not include power windows or power locks). Reconnect negative battery cable. Remove protective masking tape from painted surfaces.

Reassembly

1. Torque all hinge fasteners to specification using a calibrated torque wrench
2. Door alignment may require minor adjustment even when using reference marks; this is normal due to hinge wear patterns
3. If door does not align properly, loosen hinge-to-body bolts and adjust door fore/aft and up/down as needed before final torque
4. Verify door latch engages striker smoothly without excessive force or binding

Verification

• Open and close door 10 times to verify smooth operation without binding or sagging
• Check that door panel gaps are consistent with opposite door (3-6mm typical)
• Verify door seals properly against weatherstripping with no light visible around perimeter when closed
• Confirm door latch engages striker positively without excessive slam force required
• Test all door electrical functions (locks, windows, etc.) operate normally
• Check that door remains in any position when opened (does not swing closed or open on its own on level ground)

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