How to put in a upper door hinge pin - 1991 Ford Explorer

Examine the hinges. They may be bolted from the outside at the door side. Another option is remove the 'drop pins' holding the two half's of the hinge together. Some hinge pins are only held in with a spring clip. Your only other option is to remove the front wing and unbolt the door with the hinges still on.
To remove the pins-
NOTE THIS IS A TWO PERSON JOB!!
Proceed as follows...
Support the weight of open the door.
Tap the spring clip sideways off the thin end of the pins,
(located top of the top hinge and bottom of the bottom hinge).
Tap the bottom pin upwards then the top hinge downwards.
You might need to wriggle the door to get them to move.
REFITTING
Put the bottom pin in first as it 'drops' in and the upper pin pushes up into position.
Again, you will have to wriggle the door and GENTLY tap the pins into place.
Swopping the the pins makes it easier to line up the new door as it closes.

take to a bodyshop as will need special tools , i just wonder why you would want to do this , don't try using a drift as will cause damage to hinges

The only door bushings I am aware of are the ones on the hinge pins. Correct? If not, please clarify what you mean.
New pins come with new bushings, and the hinges are welded on so the pins are pretty much the only items replaceable. Not a fun job - because of the door stop springs you will need a spring compressor, and you will also need a special tool to drive out the old pins. However, both are available from a parts store or Amazon.
Just open the door and support it from the bottom, and then go for it, one pin at a time - for the upper pin, compress and remove the small spring, drive out the old pin, drive in the new pin and put the spring back. No spring on the bottom hinge - just replace the pin.

I have done a 100 of these.

The hardest part is going to be to reinstall the spring on the lower hinge arm. this is not a screw but rather a pin.
There are two hinges that hold the door to body.
when the upper and lower pins are removed the door will come away from body, it is important that before you remove the pins you take a look at the hinges.
Pay close att. to the way the hinges sit inside each other and the way the pins go in. see if they go from top to bottom or from bottom to top. also note where the copper bushings sit in hinges. each hinge has one pin and two copper bushings top go into hinge.
Over time the pins and bushings wear out ,making door hard to open and close. When the pins and bushings get so bad that the bushing is worn out and then the pins are now wearing into the hinge hole itself then this get tricky. if hinge hole is egg shaped the new bushings will not last. the door will hang again in a few weeks. this is where is get costly, the hinges now need replacing. i have gotten good at welding the holes and filing them back to shape but this takes skill or hole will be wrong and bushing will not fit or line up.

Here is a youtube video to help you.
Take note. put jack stands under door with cloth to avoid scratching door.this is to hold door when pins are removed. have somone help you, they will hold door on stands. the wires will still run through door, pull door away from body a little to allow room to work.remove the spring, it will fall out as you remove pins, remove old bushings, clean hinge area and holes,next install new bushings, apply lube to holes for pins and on bushings, slide door back on frame hinges and install pins, next slide lock washers on pins to hold pins. last is the spring. you will need a spring tool, you may rent one at auto parts store. hope this helps good day.

You may have to replace the hinges but most aftermarket suppliers have pin and bushing kits to repair your existing hinges. A phone call to your auto parts supplier can probably fix you up for a fraction of the price of new hinges.

When you go about fixing the door, an old bumper jack is the best tool to use, if you have one. It will support the end of the door while you remove hinges and make adjustments.Otherwise you will need a helper. BE SURE to mark the position of the hinges before you remove them so you can put them back on easily. If you don't mark them it can take a looooong time to get them adjusted properly. Hope this helps.

1. Remove sliding door trim panel , watershield, and access hole cover plates.
2. Unlatch pizza sliding door.

3. Remove latch actuator rod retainer from center door retainer hole.

4. Disconnect pizza rear door latch actuator rod from pizza remote control assembly by opening pizza clip.

5. Open pizza door sufficiently to gain access to pizza three bolts attaching pizza rear latch to pizza sliding door. Remove bolts.

6. Remove pizza sliding door rear latch with pizza remote control actuator rod attached to pizza latch, from pizza sliding door.------------- First you need to get the right tools for the job and the right parts to fix the problem.There is a hinge pin in both the upper and lower hinges and four brass bushings and there is two different size bushings in each hinge and also two hinge pin retaining washers.as for the tools you need a spring compressor,jack,hammer,punch. First open the door all the way,put jack under door,I like to use a 2by4 board on top of the jack to help spread the wieght of the door out a little,next if the door has a wireing harness in the jamp loosen the rubber insulation form both the door and the body this gives a couble of inches of slack in the wireing.Next use the spring compressor to remove the spring,then use the punch and hammer to drive out the pins.it is very hard to get them to move an first but gets easyer as they start to move.I would recomend having a helper to hold the door upright as it will fall when the pin is removed from the hinge.Onece the pins are out move the door and jack away from the body to gain more axcess room the replace the bushings,two in the door side and two in the body side,then slide door and jack back and align hinge holes and install new pins. I allways grease the bushing and pins before installing.Drive the new pins all the way flush with the hinge and install the retainers.Reinstall the spring and reattach the wireing insulation. ------- Open the door so it is directly above the bench. Observe how all the fasteners, be they bolts or pins with bushings, are aligned. Generally, the bolts and pins point toward the center of the hinge from the top or bottom, The bolts and bushings are on the body-side bracket for the upper bracket and the door bracket for the lower one. This will help. Thanks please keep updated. please do rate the solution positively .thank you for using fixya

GM Full-Size Trucks 1988-1998 Repair Information Doors - REMOVAL & INSTALLATION

R/V Series
See Figures 1, 2 and 3
If the door being removed is to be reinstalled, matchmark the hinge position.

1. If the door is to be replaced with a new one, remove the trim panels weathersheets and all molding.
   

Fig. 1: Door hinge-R/V Series

1. If the door is to be replaced with a new one, remove the glass, locks and latches.
2. If equipped with a wiring harness, remove the trim panel and disconnect the harness. Guide the wiring out of the door.
3. Support the door and remove the hinge-to-body attaching bolts. Lift the door from the truck.
4. Install the door.
5. Perform the alignment procedures indicated below.
   

Fig. 2: Door hinge components-C/K Series



Fig. 3: Removing the hinge spring


C/K Series

1. On trucks with power components in the door, disconnect the battery ground cable.
2. On trucks with power components in the door, remove the cowl side vent cover.
3. On trucks with power components in the door, disconnect the wiring going to the door, under the dash panel. Feed the wiring through the door pillar.
4. Cover the door hinge spring with a heavy towel. Using tool J-36604 or its equivalent, insert the blades of the tool between the spring coils and turn the barrel nut to compress and hold the spring. Remove the spring using the tool.
5. Remove the lower hinge pin retainer.
6. Using a plastic or rubber mallet and locking pliers, remove the lower hinge pin.
7. Install a bolt through the lower hinges to hold the door while removing the upper hinge pin.
8. Remove the upper hinge pin retainer.
9. Remove the upper hinge pin.
10. Support the door and remove the bolt from the lower hinge.
    

To install:

1. Position the door and install the bolt in the lower hinge.
2. Install the upper hinge pin. with the pointed end up.
3. Install a new upper hinge pin retainer.
4. Remove the bolt from the lower hinges.
5. Install the lower hinge pin with the pointed end down.
6. Install a new lower hinge pin retainer.
7. Using tool J-36604, install the hinge spring.
8. On trucks with power components in the door, connect the wiring going to the door, under the dash panel. Feed the wiring through the door pillar.
9. On trucks with power components in the door, install the cowl side vent cover.
10. On trucks with power components in the door, connect the battery ground cable.

ADJUSTMENTSee Figure 4 The holes for the hinges are oversized to provide for latitude in alignment. Align the door hinges first, then the striker.
C/K series utilize hinges that are welded to the door and frame. No adjustment is possible except when replacement hinges have been installed.



Fig. 4: Door adjustment check points

1. If a door is being installed, first mount the door and tighten the hinge bolts lightly.
   

If the door has not been removed, determine which hinge bolts must be loosed to effect alignment.

1. Loosen the necessary bolts just enough to allow the door to be moved with a padded prybar.
2. Move the door in small movements and check the fit after each movement.
   

Be sure that there is no binding or interference with adjacent panels.

1. Repeat this procedure until the door is properly aligned.

R/V Series:
Door edge-to-rocker panel: 6mm Door edge-to-roof panel: 5mm Door edge-to-rear pillar: 5mm Door edge-to-front pillar: 2mm
C/K Series:
Door edge-to-rocker panel: 6mm Door edge-to-roof panel: 6mm Door edge-to-rear pillar: 4mm Door edge-to-front pillar: 7mm Door front edge-to-fender: 5mm

1. Tighten all the bolts to 26 ft. lbs. (35 Nm).

Shims may be either fabricated or purchased to install behind the hinges as an aid in alignment.

Hope this help, TY for using Fixya (remember comment and rated this). Good luck.

most of these cars the only part you can change is the pins if your are bolted on you can adjust loosen the bolts one hinge at a time to adjust... when changing a door with live hinges you should mark ware the old hinges were so you can put the new hinges in the same place
if you car has welded hinges you have to bend the door at the hinge or door support ( its not as hard as it seems)

try using engine oil.put oil in a little can oiler.oil the door hinges pins and bushings.if it still sqeek.door hinge need adjustment.or the door hinge pin and bushing need replacing.

Hinge is either loose or broken. tighten or replace hinges.