After rebuilding the door hinges the upper hinge has some up and down movement (play). The bushing went in tight but once in, it will move up and down slightly.
I'm thinking that might be a problem.

 

The weight of the sagging door has likely sprung the hinge. Use a large vise or a trusty hammer to adjust the "wings" of the hinge to remove MOST of the play.

There needs to be a little play to prevent the door from binding.

Also soak the oil-less bushings in some light oil. Who knows how long ago they were made and the oil has evaporated.

Some of the non-box hardware stores sell brass washers one could use to remove the play without adjusting the hinge "wings".

Ron

 

I wonder if the bushing hole is elongated from the last bushing wearing thru.

 

bushing hole was round but once tapped in the new bushing can move up and down in the hole

 

Up/down motion is irrelevant. Gravity holds the door down, and only one of the two hinges will actually carry the vertical load. Radial motion is what matters. That should be very tight.