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Discussion Starter · #1 · (Edited)
when i bought my 96 1500 (ext cab with no rear doors) the hinges were already worn out so i adjusted the striker down to compensate.

yesterday with ice all over the truck i pulled the door open with 1 hand and the latch was falling inside the door, :SHOCKED:the sheet metal is ripped and the latch flops around. the door wont stay closed at all.

has anyone ever seen this before?

is there a repair kit or will i need a door shell ?:thk:

the door is not rusted , which is amazing for a Michigan truck.

any help will be greatly appreciated, thanks.
 

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Can't say I've ever seen this. Have you spoke to a body shop to get their opinion?
Might be worth getting a door from an auto wrecker. :4-dontknow:
 

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im from MI as well and my door just did this last week. i found some washers and puthem in there. i was going to weld it but the sheet metal is way to thin. might wanna try that first. other than that you might wanna try and find a door from a junk yard for now and then save some money and buy a new door shell.
 

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I'd get a body shop to repair it (weld) but get a quote first...a junk yard shell may be cheaper.
 

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My hinge is worn, I did a simple home made bushing repair since the new kits you have to take the door off and drill it out. My door sgged but not as bad now after the quick repair I did.. but yes my door is torn where the latch is on the door, dont know why or how that happened other than the kid I got it from did alot of off roading and maybe the excess stress caused it to tear. I want to replace my upper hinge but just havent felt like messing with it myself ( doors are heavy ) lol
 

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I'd get a body shop to repair it (weld) but get a quote first...a junk yard shell may be cheaper.

yes you are right a junk yard shell is cheaper but from working at a body shop and see alot of this on other cars and as a certified welder the only options would be to tig weld it and you still run the chance of blowing the sheet metal apart from how thin it is.
 

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yes you are right a junk yard shell is cheaper but from working at a body shop and see alot of this on other cars and as a certified welder the only options would be to tig weld it and you still run the chance of blowing the sheet metal apart from how thin it is.
True, I tried to MIG mine on the lowest setting and all it did was blow holes in it.
 

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I had an issue similar to this years ago on my first car (88 Pontiac grand am) pulled the handle up to open the door and tore metal about 1/4 inch it cause play in the outside handle so it wouldn't allow it to open unless u held handle in place while lifting up ( very frustrating) I repaired the issue by taking a punch and hammer and pushing the torn metal back in place and then tack welding the tear to avoid it happening again hope this helps
 

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On older vehicles, we used to purchase a hinge kit
some times you get lucky & only need the hinge pin
 

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I had to braze mine once and it held up pretty good. The only problem was that with that much heat there tends to be warping of the metal, and it had to be done in small tack spots and connected.
 

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I know I'm late to the party on this one but mine cracked right by the latch too. Put my Lincoln on the lowest setting and took my time and was able to weld it up. It's not pretty but it works until I replace the door. Only think I can recommend if you do this is to stuff a wet rag in the latch or else the plastic guide likes to catch fire...
 
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