About those hinge pins; I had a nice write up with pictures but my hard drive failed and wiped everything. I never got to back up the info. So what I post here is from memory and working with my old door hinge. My truck is a 96 2500 2wd. My door had been sagging for some time. I checked the hinges by lifting the back side of the door and could feel and see movement in the hinge. My door latch did not align with the latch pin on the door frame. The real danger here is that I needed to slam the door to close. With this misalignment, you can crack the sheet metal around the door latch. This then gets expensive and time consuming. I have seen a few pictures posted of doors with damaged door latches.
The pins that came with my truck are stepped pins. That is the head part is larger than the pin part. So, the two holes on the hinge are different sizes. See picture you can just make out the different size. On my new hinge the pin is one size.
For this repair I needed to drill out the holes for new hinge pins. The hinge pin kit that I used I found at O’Reilly Auto Parts. It is kit number 384232. You will need 3 kits; upper hinge, lower hinge and bracket. The kit is about $7.00 each.
It comes with 2 pins, 2 large bushings, one smaller bushing and 2 pin clips. The 2 large bushings are missing in this picture. The two pins are different length and diameter.
Now comes some memory work. I made a door holder and pressed the old pins out with a C clamp and a piece of tubing. I wanted to save the old pins. You can tap or cut them out. My old pins were held on by a compression type washer that I pried off. Then I removed the hinge from the door. Before you do this, mark the location of the hinge so you can reinstall it in the same location. This way you should not have to do any adjustments.
I drilled out the door hinge bushing holes to 31/64th. I drilled all the holes in increments. This helps to keep the hole square, prevents wobble and an out of round hole. I used a 3/8th bolt, washers and nut to press in the 2 new bushings. On the truck side hinge I drilled the holes out to 3/8th to accept the pin. Drilling can be done with the hinge installed. All this is for the door hinge pin.
The door detent bracket pin is a bit different. The pin is mushroomed in so you have to cut it to get it off. As I recall the small bushing in this kit is too small for the bushing hole. So there are two ways you can go. One way is to drill the hinge pin holes to 3/8th on the hinge. Drill the bracket hole to 31/64th and press in a large bushing. This way you use one large pin and one large bushing. The pin will be a little long but with a small spacer that is no problem. When I did this job I didn’t think about using the large pin so I did the bracket a bit different. I drilled out the bracket to 31/64th, pressed in a large bushing and then pressed in the small bushing into the large bushing. This way I used the small pin. It worked really good until I messed up my door. If I had to do over I would use the large pin and bushing.
Since I had a lot of wear by the up and down movement of the bracket. I supported it by adding some tubing above and below the bracket. This holds it in place. You can see it in these pictures. You can also see the double bushing.
The dimensions I give are from memory and should be accurate but double check with the hinge pin kit that you use. Hope all this helps.