Door Hinge Weld Repair - Anyone have this done?

[SoonerBrink]

By drivers front door hinge had been making a weird noise randomly.

Finally got the truck to the dealer while it was making the noise.

They said it was the welds on the door.

Dealer had warranty repair approved by ford. Said I need a new door, new mirror, then paint door and install. (not sure why they need a new black mirror).

I am concerned about the paint not matching.

Anyone else had this issue? Did they fit it this way or another way?

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[Waterick]

How old and what color is your truck? Has it seen a lot of sun or harsh weather? Most body shops can get late model paint near perfect from what I've seen if their decent.

 

[Cancunbadlands]

No worries, the Ford Body Shop is gonna perform a paint blend it to match the panels

 

[notfast]

Dealer had warranty repair approved by ford. Said I need a new door, new mirror, then paint door and install. (not sure why they need a new black mirror).

I am concerned about the paint not matching.

The body repair guide probably specifies that the mirror has to be replaced if the door needs to be painted. Not entirely unheard of for mirrors, but it's more common for plastic trim parts that clip or are taped on. There's probably enough of a chance that the mirror or any of its mounting components or connectors might get broken during removal that it warrants just replacing the mirror rather than making another claim.

When my Mazda went to the body shop, I got a box of new-in-bag reflectors, badges, and other parts when I got the car back. They were approved to order them but were able to carefully remove the old ones, so they just told me to keep the new ones.

Any body shop worth their salt will be able to match the color and blend it into the surrounding area, especially on a newer car. It becomes challenging to repaint pearl white on a ten-year-old car that spent its whole life outside in Arizona, but still not impossible.

 

[SoonerBrink]

How old and what color is your truck? Has it seen a lot of sun or harsh weather? Most body shops can get late model paint near perfect from what I've seen if their decent.

2023 Model. Gray. XL. Waxed a couple times. Not a lot of sun or harsh weather.

 

[jeffrol48197]

My truck started this a few weeks ago, found same problem - Ford authorized door replacement on my truck as well, I would rather they FIX it and I keep factory paint which is harder than sprayed repair...Waiting to hear if they will do my request or if will force replacement on me -- I THINK THIS WILL BE A BIG PROBLEM for many people in the coming months and/or years...(3.5 years old and 22k miles...sad)

 

[notfast]

My truck started this a few weeks ago, found same problem - Ford authorized door replacement on my truck as well, I would rather they FIX it and I keep factory paint which is harder than sprayed repair...Waiting to hear if they will do my request or if will force replacement on me -- I THINK THIS WILL BE A BIG PROBLEM for many people in the coming months and/or years...(3.5 years old and 22k miles...sad)

I mean, depending on where the crack is, it may be possible to just grind the paint in the affected area and weld it back together, but Ford probably wants a "one and done" bolt-on repair. Too many variables with the size and location of the crack and the skill of the body shop technician to weld it back together.

Though if it were me, welding it back together would be the way I'd pursue first because unless they also weld in a reinforcement plate or the new door has some other design change, it'll probably just crack again but out of warranty.

This is starting to remind me of the door cracks that plagued the '97-'04 F-150s.

 

[BlueSpec1]

Similar to:
Customer Satisfaction Program 23B56 - Supplement #1
Certain 2020 - 2023 Model Year Escape Vehicles Inspect Front Door Check-Arm Reinforcement Spot Welds
https://static.nhtsa.gov/odi/tsbs/2025/MC-11012204-0001.pdf

CSP Campaign 23B56 Front Door Check Arm Weld
https://www.fordescape.org/threads/csp-campaign-23b56-front-door-check-arm-weld.123691/

 

[jeffrol48197]

I mean, depending on where the crack is, it may be possible to just grind the paint in the affected area and weld it back together, but Ford probably wants a "one and done" bolt-on repair. Too many variables with the size and location of the crack and the skill of the body shop technician to weld it back together.

Though if it were me, welding it back together would be the way I'd pursue first because unless they also weld in a reinforcement plate or the new door has some other design change, it'll probably just crack again but out of warranty.

This is starting to remind me of the door cracks that plagued the '97-'04 F-150s.

Yes, my body guy was going to a spot repair and paint the door jamb area where welded, NOT break the skin paint - I almost want to do it this way to make sure it doesn't happen again...Difference is $530 versus 'free', if done their way...

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