I have just had to replace a second hinge on my Access Hatch Cover. The first one happened in Broome while on my latest trip, and I had to make do with what tools I had available. This latest one I saw at home, which gave me an easier job I will explain below. Refer also to the photos.
The hinges, Coast part number 600-09004 Coast Door Hinge Black fit a range of Coast hatch covers, and retail around $13, when you can find them. I now carry a spare in the van.
The hinges are secured to the hatch cover by one screw accessible from the inside of the cover, but the other half of the hinge is secured to the hatch FRAME by two screws. To replace the whole hinge would require removal of the frame with all the associated problems of replacing sealant etc. It would be quite a job.
However, I noticed that the hinge has a grub screw at each end, which keeps the hinge shaft in place. Therefore I figured that if I could remove the grub screws and the shaft, I only needed to replace the broken part of the hinge on the cover a much easier job.
A 2mm allen key is required to remove the grub screw, and a key with a ball on the long end makes it easier, but not absolutely necessary.
The main problem is that the design and shape of the frame near the hinge makes it impossible to remove the grub screw or shaft without making room. In Broome, I used a file to remove enough material, but at home I used a sharp chisel and light hammer see photos to see how much material had to be removed.
Once you have made room, get both of the grub screws out. Then use the end of the allen key to push the shaft out and remove the two spacers.
Unscrew the broken half of the hinge from the inside, then reassemble the new half into place.
Finally, mask the area and give the frame a quick spray of gloss black paint.
The latest one took less than 30 minutes to replace.
