Just opened my door and it was hanging by just the top & middle hinge. The large bottom hinge was not longer attached to the door. The 2 bolts broke off now I need to replace. Need to know what size of bolts? Is this a common problem for the Beetle?
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the correct fix is to replace the door hinges
the next best fix is to loosen of the bolts that hold the door hinges to the door pillar and lift the lock side of the door
then while holding the door up , retighten the hinge bolts
once you have removed the headlight assembly and remove the bolt behind the headlight assembly, continue locating the 10mm bolts attaching the fender along the top side, along the bottom in front and behind of the tire, open the drivers side front door, look into the opening between the door hinges and with a flashlight and a long extension on your ratchet you will then remove the two bolts between the fender and door, one on top and one at the bottom. you also have to remove the retaining bolts that attach the inner fender liner to the fender.
The hinges are held on with large bolts that are visible when the doors are open. A "Door Hinge Pin and Bushing Kit" also known as a "Door Hinge Repair Kit" can be purchased from rockauto.com for under $20.
If you have any electrical controls in the door open the panel and disconnect them so you can remove teh door from the wiring harness. otherwise, open the door and support it on the outer edge away from teh hinges, use an impact driver with proper bit fitted to it, available at Auto Zone, Pep Boys, Advance Auto, or Sears (it uses a hammer to generate torque energy to break the torque in tight spots like an impact wrench) Remove the lower Hinge screws or bolts (These are usually a large Phillips head or a Half Inch bolt head), Then remove the upper retaining screws or bolts. To make it a little easy to handle if you are doing this by yourself, remove all of the screws or bolts from the lower hinge then put 1 back in a couple of turns just to hold the hinge. Repeat the process for the upper hinge. after doing this empty your hands, lift the door slightly and remove the 2 screws or bolts you put back in. after removing the door remove the hinges from the door side so you can use them in the new door.
If your door sags it means the bushings in the door hinge are worn out, but there is a way to adjust it without replacing the hinges if they aren't too bad. If you open your door there are bolts that attach the door hinges to the A-Pillar, most of the time they are accessable from the outside. First get a car jack and position it under middle edge of the open door, put a small piece of wood on the jacking point to protect the door. Loosen the bolts to the hinges and raise the jack so it raises the door up. tighten the bolts on the hinges back up and open and close the door to determine if the door was raised enough to eliminate the sagging.
Before attempting to adjust the door, you need to check the wear on the hinge pins. Open the door fully and look at the middle of the hinge. See the pin there? Lift up on the latch side of the door as you watch the hinge pin. If you see the hinge moving around the pin or see the pin shifting back and forth then the metal grommet the pin goes through is worn and needs replacing. Motormite makes a replacement pin set that comes with new grommets ( or bushings to some). It's not so hard to change, but it can be a little tricky. Jack up the door to relieve the pressure on the pin.Start with the top pin. Watch the pin as you jack and keep going until the pin is in the middle of the movement range. Tap the old pin out and then inspect the grommet to see if it's worn past the outer edge of the metal. If it is worn past the edge then you'll need to replace that hinge. Otherwise, you can use that old pin to tap out the old grommet, and replace with the new one, then the new pin. slowly release the pressure on the jack and watch the new pin for excessive movement, then do the bottom pin and grommet.. Test door swing and alignment. If the door still hits low on the catch post, loosen those torq bolts after lifting the door slightly and now lift the door the distance it was low plus 1/8 inch. retighten torq bolts and release jack, then retest the door alignment to the catch post. Don't let the door strike the catch post hard - just let it slowly come into contact as you watch for alignment. Repeat procedure until door lines up centered on taht catch post. Good luck!!
Door hinges are adjusted by slakening off the M10 (multi spline) bolts top and bottom.3 on lower hinge and 2 on top hinge.Both hinges have a securing bolt accessed from INSIDE the A pillar.Remove kick panel to access bottom bolt and dash end panel to access upper---this one can be tricky.
go look at the passengers side. take note of the door seam and fender seam width. its about the width of a piece of cardboad. additionally look at the door hinges on the passenger side. it may or may not have washer shims. if they do/dont then just match up with passenger side. it takes 2 people to hang the door. screw in door hinges "finger tight" just to take off the weight of someone holding the door. play with the hinges until you can open/close door without binding or crimping fender at the seam. do not over tighten hinge bolts until the door opens/closes unobstructed. bottomline 2 people needed. slow and tedious job. you may have to add or take shims(washers) out for good fit. note that you may have to add shims to the inner door hinges or to the fender hinges where they meet. hope this is clear instructions.