Tom Bennett's XJ-S Door Hinge Repair Guide
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As I started this thread recently, I thought it only fair I should share my FIX with everyone. Here goes,

1. Go to your local Chevy dealer and buy 2 standard Chevy hinge pins and 4 bushes.
Pin # AG20046147
Bush # AG16632193
This will fix top and bottom of one side.

2. I should tell you that there is a Quick fix here, if the original brackets pin holes (those that are bolted to the body) are not worn oval, you can insert the Chevy pin straight away, you only have to drill the hinge bracket on the door side to accept the new Chevy pin.

3. The permanent fix is this. Pull out the old pin and what is left of the bushes, take the Chevy pin and bushes to your local machine shop ( or diy if you have a drill stand) and have them drill out the top and bottom of the hinge bracket to a diameter and depth to suit the Chevy bush, do not drill all the way through as this will weaken the bracket!

4. Before pressing the Chevy bushes into the bracket, check the clearance between both parts of the bracket, The Chevy bush has a lip and you need to make sure that both parts will fit together with the new bushes in place, the main bracket is cast steel and very easy to file to get the required clearance. Note: As the new bushes are bronze, it was once standard practice to soak new bushes in oil for 24 hours before use, this is what I did!

5. The brackets from the door side will need to be drilled just big enough to accept the new pin, then tap or press the new bushes into place, assemble the bracket and refit to the car, Voila! A hinge that will not fall apart again.

The Cost: I got the Chevy parts for $10 and the drilling cost me $5.

I hope this is of some use to all you guys with hinge problems.