On my 98 Wrangler Sport, there is a definite "lip" about half way down in the hinge hole. The new bushings are about twice the length, or depth of the ones that came out. Either they are the wrong bushings, or there is a second portion of bushing that remains in the lower half both hinge holes. There is no way that the new Delrin bushings would fully seat, because of the lower half being occupied by either bushing, or smaller ID hinge hole. The bottom half cannot be easily driven out (if at all)...and I will have to continue working on it tomorrow, as I'm out of patience and daylight.
Does anyone who has installed new bushings recall the hinge hole having a "stop" about half way down (all the way to the bottom of the hole)....where the ID is about 2mm less than the upper half?