you do not have to get the hindge pin all the way out. if you look at the hindge pin carefully you will see it is a different thickness at different points. The idea is to fit the flap onto the thinner points of the metal pin and tap the pin with a punch so that the thicker points go through the plastic supports on the flap.
The pins do sieze. you must get the thinner points completely in view, clip the flap onto them and then knock the thicker parts through.
Thats how we used to fit them in our dealership, it was a job you did whilst the customer waited, but it was also a 2 man job. getting at the pin to knock it through whilst holding the flap is not easy.
one of the other peugeot lads on here may well know an easier way but the way i have described is the quick way as we worked on a bonus scheme.
Friday, 5 January 2007