I have a similar problem on my 1 ton, front hanger on the right rear spring, although it is only slightly worn, no noises yet.
If I put the truck back on the road I'll fix it, my plan was to replace it with a better used one. As they are not likely to go bad, and a used one has a good chance of being OK, obviously I would check it out before I bought or installed one.
Simplest way to solve the problem is to remove the old one and bolt the new one on with grade 8 frame bolts and nuts.
Proper way to do it is to re rivet the new one in place, just like the original, and this is the approach I will take.
Another possible solution would be to ream the old bracket oversize and permanently install bushings to take up the difference, or an oversize pin. This could all be done on the truck. This method would need some evaluation to be sure you have enough wall thickness. If an oversize pin is used I would look for a standard sized one for another application that may work. I would avoid having one made, because to make a new pin the right way (so it will last and be reliable) could be expensive.
I would not consider welding and re-machining, because to do it the bracket must be removed, and at that point it will be far cheaper to install a used one.
Grigg
