Is there a way to make door adjustments to the Driver's side without going thru the battle of pivot pin/busing replacements? Sounds like a lot of work and only the top pin seems a little sloppy causing the door to sag approximately 3/8". If the pin replacement is the best solution, can these be purchased at like an Advance Auto Parts store or ordered thru a Chevrolet dealer? Thanks, Ni
Yes, you can adjust the hinge to remove the slop, at least on a temporary basis.
Open the door and set up a hydraulic jack to support the door at the rear. Cushion the jack pad with a block of soft wood to both spread the load and protect the door. I also like to support the frame under the door opening with another jack or blocks. That way the body doesn't move when you are getting in and out. Carefully mark the position of the striker pin on the rear door jamb and remove it. Loosen the upper hinge at the pillar just enough to get some movement in the hinge. If the upper hinge is not worn very badly, you can usually leave the lower hinge tight, which will make the job much easier. Jack up the door a bit, maybe an inch or so, snug down the hinge bolts, lower the jack and check the door fit.
Repeat the process until you get the door aligned with the quarter panel. Once you're satisfied the door is aligned, replace the striker pin. Even if you marked it carefully, some minor adjustment of the pin may be necessary for smooth latching.
Post again if you have any problems.
Good luck!
BTW, pin and bushing kits are a stock item at most parts stores, usually about $5 per hinge.
Bill