I need to replace the bushings on my door hinges and the only way I can see to remove the top pin is to cut the head off with a Dremel cut-off wheel and drive the pin back down through the hinge and out the bottom.

Major PITA. The new pin appears to have to be installed up through the bottom of the hinge.

 

There are two ways to do it.

First, cut half of the head off of the pin and it will clear the fender lip.

Second, cut the pin in half, and remove it from top in two sections.

 

It will come out the top.I always remove the door with hinges attached.
edit -oops sorry I see your doing it without removing the hinge.make sure the hole that the bushing goes in is still round.

 

They should be, they don't turn in the hole.

 

Sometimes if the pin wears through the bushing and into the steel it will elongate the hole.If you put a new bushing in without the steel to back it up it just crushes the new bushing.I usually end up welding the hole a little and then filing it.

 

Just did this 2 weeks ago.....
Thought I could do this without taking the door off, but after trial and error, decided it was the only way.
1. Remove upper hinge cover and loosen the 4 bolts.
A. Make sure to have a box or support underneth door.(I used a box and was able to rest door against a wall in my garage.)
2. You have to remove the door panel to get to the bottom hinge bolts.
Once panel is off, and door is supported, loosen bolts and remove all upper and lower hinge bolts. I had read a previous post that you should grab a spray can a shoot the bolts for easy install of your bolts for alignment, however, after installing bolts back in I found that I still needed to loosen and adjust positions of bolts several times for proper door spacing and latching.
3. Once door was off, I used a punch or screwdriver to drive the pin up and then used a dremel to cut the pin in half, like durango_boy suggested. After installing new bushings, I couldnt figure out how to install new pin without damaging the fiberglass so I just ended up using my dremel (love that tool..!!!) and removed about half the lip on the new pin and installed easy after that and pressed the new pin down through the pin holes.
4. Now just reverse the procedure and (this was the worst part for me) slide the door back on the hinges..(I did this by myself). Took a few good cuss words, but finally went back on.
5. Now just check your alignment and loosen and tighten several times untill you get the best fit.

Hope this helps......
Happy Thanksgiving everyone...
God bless America....

 

I've been down that road!

 

Thanks for all the help. i started the job, I used my engine hoist and some straps to support the door, then my wife came home early and I decided to abort the job because I know this is going to take some time and I didn't want to feel rushed. I think I will do it over the holidays.

 

I found a Help! repair kit that had thicker, splined bushings. I drilled the holes in the hinge out a bit so they were round again, then whacked the new bushings in place. Tapped the pins back in and Presto! - no more problem. My original pins were in good shape, so I reused them. The Help! pins were much longer.

 

Take some care when installing the bushings. They are brittle hitting them in with a hammer is not good. They will crack. I use a nut an bolt and a socket to press them in.

 

So you bought Help! pins and bushings and not Vendor stuff?

Hmm...that'll save me some time. I may have you come in with me on this project.