I have some pretty serious 444 Door Hinge Pin Wear.
I have the car disassembled and have been able to break loose some of the large slotted head screws. I will get them all out next week.

Does anyone know if the 544 door hinge interchanges with the 444 ?

Maybe I would do better with good used hinges.
If I attempt to repair my hinges, there is a good chance mine may have enough wear in the hinge in addition to pin wear, that I might need oversize pins (which may require an exact metric drill for a tight fit).

Any thoughts/ help would be appreciated.
If any of you have some good used hinges, let me know price for your hinges.

Also if oversize pins are available (where to get), what drill size to use.

Unusually, all of the hinges are same, so all parts are interchangeable. Lower hinges wear the most so you might get away with new pins for the top ones. Lowers might be too worn and need oversize pins. Some more modern cars use HD roll pins. Ford Escort? Ford will use anything cheap, but they do expand a bit to take up wear.

Pin part #91053 All 544 and Amazon front doors.

I like the sound of the Heavy Duty roll pins.

Several choices here https://www.mcmaster.com/roll-pins

Seems like they would keep constant tension for a long time after drilling/ reaming the hole to the proper size.

Perhaps screw a large self tapping screw in the top after fitting to stop them falling out and/or block up the bottom of the fixed hinge. Keep them lubed.

The door hinge pins are still available, but they aren't oversized. Both door hinge halves are not available, but they are the same as the 544.

You might find an "oversized" hinge pin that's for another application that would work, but it might be easier to buy some good used hinges or rebuild your old ones with new pins.

FYI, I probably have a good used set of hinges.
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Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com