A lot of people on here after replacing bushings have reversed that pin and drilled for a cotter key so they could do it again without taking door off.
I'm one of those guys and I'll do it from now on.

While I agree with you Mr. bake74, you could always be creative with a cut off wheel and cut the top pin in half to get it out as it is. Remove the bottom pin conventionally, and pull the door off without removing the hinge halves from either the cab or door.
Of course that would still not guarantee you that after you replaced the bushings and pins, that your door would be perfectly aligned. But, it could be very close.
Anyway, just a thought.
I say all this just because I really stink at body alignment and I fought with my doors to get them set properly. But in the long run, I did win.
