Can I fix this?


 
I would rather use a file and increase the hole in lid and firebox just a touch so that the pins have a little more play. I only worked on two of these Genesis and both had stuck pins. One I had to drill out . But this never happened to me on the older grills.
 
I think there is a reason that Weber uses steel. The aluminum might shear off after a while of wear and having the lid open hard.
If you can find Stainless steel, that would be a good replacement.
 
Chris:
Larry is spot on about the corrosion. That is why I free them annually and use some emery paper on the pins to keep things movable. The firebox bolts, I back of the nut to protect the threads and tap, not hammer on the nut to break them free. Front seldom has issues unlike the rear bolt that catches plenty of gunk from grilling. I think after awhile aluminum pins would wear down to the point that they would fail.
 
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