2nd Gen Non-Engine/Transmission Cracked Drivers Door

[hankhaken]

The drivers door on my 96 ext cab is cracking around the latching point. It looks impossible to fix other than to replace the entire door. Any Ideas?



Hank

 

[Joe Mc]

There was another member not too long ago that had his repaired - he posted before and after pictures. He wasn't very pleased with the job as the shop didn't smooth off the welds etc - basically poor craftmanship. Mine is cracked right by one of the bolts that holds the latch to the jamb pan on the door. I used a small fender washer and tightened the bolt as much as I dare until I can mig it from the inside and outside.



My guess for the best reapir is: remove inner door panel, window all the way up, remove latch device, make sure there are no other parts/wires etc in the way. Tape off and area you are comfortable removing the paint from on the jamb. Grind, sand or whatever you choose to remove the paint along the crack, drill a hole at the end of the crack where fresh metal is so the crack will not continue to creep along after the repair. Make the cracked sides level with each other and mig a spot to hold then stich ending at the hole - fill the hole with weld. Do the same on the inner of the door cavity. Grind high spots down, putty, smooth, prime and paint. I doubt you should need a new door.

 

[hankhaken]

Thanks for the reply. Do you know why that happened?



Hank

 

[Joe Mc]

My bolts became loose on the latch and I didn't notice. So after closing and opening complicating by vibrating down the road the metal was stressed and cracked - my best guess.

 

[JMLambert]

Hank, I had the same issue on my 99. The door cracked around the driver side door where lock is kept in place by the bolts. I took it to a reputable auto body shop and they welded the cracks and also put a plate inside the door facing and welded it in. This was 2 years ago and I have had no further problems. The cost was $150 versus 1500 to 2000 for a new door. If you look real close you can see where it was repaired but it was not an ugle patch job. Hope this helps...

 

[hankhaken]

Thanks for all the help on the door issue. I have an local body shop going to do the work. 175... and replace the hinge bushings I had about . 5 inch drop when opening and closing the door.

Sure is nice to get some mentorship from great folks.





Hank