Excellent advice by all; although I didnt drill a cotter-pin - good after thought. I got by; by lining the door back up with a floor jack and punching the pin back up into the hole last night (one bushing was dissenegrated.) Then today I went to the HELP area of my local Advance - and found a Dorman P/N 38407 and another Pin that was 2 mm shorter - I bought both and will return the 38407 the shorter one matched the one I pulled out. Either would work fine
After reading your posts and some old posts from pennocks what I did was lower the door far enough to expose both the top hole and the bottom. the top hole I have to punch out the bushing, but the bottom hole was missing that one. I put both bushings into the door hinge and left the car hinge empty. For the bottom part of the door hinge I placed the bushing up into it, this put the brass washer part of the bushing inbetween the car hinge and the door hinge. (the idea about the washer was taken from Ogre's cave. ) the top bushing i just slowly hammered into down into the top door part.
So now I have a smooth closing door again (i scratched the paint on the 'step' to get into the car when the hinge popped out) oh well live and learn..
So what disaster is next? I love the little notch I have....
The point of this mid-life crisis car is to get all the bugs worked out over the next year and get the gas mileage up and pass it to my son when he turns 16 in Feb. 2014. Its a 2.8 3speed auto - I brought it up from 15 MPG to a solid 20. now i am trying to tweak the rest of it.. wow I will start a new post soon for this one.
Randy