The new bushings come in two sizes: .010 & .020 oversize. Best to have both on hand before starting the job. The bushings are splined so they do not rotate when the door is opened and closed, and they must be pressed into the hinges. Try the .010 bushing first, if it's sloppy, use the .020 bushing. Reaming should not be necessary. The hinges MUST be square, and the pin should slide in easily, with no binding, BEFORE hanging the door. If the bushing fits too tightly in the hinge, the inside diameter will be distorted and the pins will bind. The pins are splined to the other half of the hinge so they rotate when the door is opened and closed.

Toocute350
 

I have the same problem with my driver side hinge on the door it self.Not the hinge on the cab.I talked to a guy named eddie awhile back at total automotive.I told him my situation he told me about the over sized bushing size also.The top pin hole on the driver door is ovalon.I will try and get a oversized bushing in it and then fill it in with jb weld.Thanks for posting this matter.You think GM Would have made smaller hinges like the newer gmc and chevy trucks.I guess having power locks and window`s add alot more weight than normal but still.:)

I repaired mine three months ago and used DuraCraft Epoxy also and so far so good, and that's with my daughter using it. :icon_razz:

I just had to replace the passenger front ones last weekend. That side is still using factory sized bushings, the tops completely fell apart... The driver's side with the oversized bushings though, still like new almost a year later :)

Where did you get the over-sized bushings? Links please.

Links are in the first post, but they're dead, looks like they no longer produce them any more unfortunately... shame too... seemed to be the only solution short of welding the bushing hole shut and redrilling it for a stock bushing...

Part numbers from the links above were as follows:

A quick google search should give you some purchasing options.

I have updated the links in the OP as well.

Oh nice find, I actually could not find them! Thank you very much sir! :icon_worthy: