Is it possible to get the upper hinge pin out without taking the door off the hinge first? I don't think so, but I haven't seen anyone talking about removing the door from the hinge before replacing the pin.

What vehicle ?

Did it on my 77 van.
Knocked the old pin out with a punch and hammer.
Top first, then the bottom hinge.
I did support the door with a board and a floor jack.

It’s a 1989 D100. The door panel curves inward above the upper hinge so it seems impossible to get the pin in or out.

Might it be easier to remove the panel than the entire door?

I did mine with the doors removed. They were coming off anyways for other reasons but yeah it is tight up there.

Not positive but I believe he's talking about the outer door skin curving in over the hinge making it hard to get the pin in the top of the hinge.

Didn't think of that.
Might just be easier to remove the door.
Get a friend to help, then it's not that bad.

Yes, that's what I was talking about. I may have used the wrong words. I've already done one door but the other one only needs the top hinge replaced. I'd like to replace only the top hinge without removing anything else, but I don't know if it's possible. It sure doesn't look possible.

I did just the bottom hinge on my 92 a couple weeks ago, Didn't want to deal with disconnecting the power windows & locks - really wasn't too hard. I did support the door during the process.

would it possible to take the upper hinge off the door-----with the door supported by a cherry picker----lean it away a couple inches---change out the pin?

I like that idea.
If it's like my '76, one bolt accessed from the out side and two from the inside, under the dash.
Would take a lot of patients,.
Not my strong point.
The are only two bolts going into the door.
Leaving the bottom hinge attached should help with re-alignment.