Drivers door stop spot welds came loose

[garyp]

22 xl drivers door spot welds hold the door stop arm broke loose. 28,000 miles. Never had any problems before. Further investigation looks like a really flimsy area. Not heard of anyone else having issues with this. Re welded it yesterday but the metal is really thin there. About 6-8 spot welds originally, all broken loose

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[BlueSpec1]

Similar to Escape door check arm. https://static.nhtsa.gov/odi/tsbs/2025/MC-11012204-0001.pdf

10/2/2025
22 Lariat - Broken driver side Door Check https://www.mavericktruckclub.com/forum/threads/22-lariat-broken-driver-side-door-check.73854/

8/11/2025
(2023) Door Hinge Weld Repair - Anyone have this done? https://www.mavericktruckclub.com/f...air-anyone-have-this-done.71525/#post-1182644

7/15/2025
(2022) New noise - clicking sound when open the door https://www.mavericktruckclub.com/f...-sound-when-open-the-door.70193/#post-1162921

11/29/2024
(2022) Maverick Warranty coverage AGONY! https://www.mavericktruckclub.com/forum/threads/maverick-warranty-coverage-agony.57793/post-976489
He tells me it only needed a door reinforcement kit installed and respray. So I look at the door stop and there are now pop rivets in my door.

11/7/2023
(2022) - The door broke https://www.mavericktruckclub.com/forum/threads/the-door-broke😮‍💨.39172/#post-701716

Escape CSP snip:

 

[Glen Baker LLC]

https://www.mavericktruckclub.com/forum/threads/the-door-broke😮‍💨.39172/

 

[mwelby]

22 xl drivers door spot welds hold the door stop arm broke loose. 28,000 miles. Never had any problems before. Further investigation looks like a really flimsy area. Not heard of anyone else having issues with this. Re welded it yesterday but the metal is really thin there. About 6-8 spot welds originally, all broken loose

Looks like they didn’t fix the problem since the same episode with the 2020 escapes. Mine was recalled but the turds only replaced and reinforced the front doors hinges. I guess they figured the back doors didn’t get used as much so they could get away with doing only the fronts and hopefully the rears would’nt fail until after the warranty Had expired.

 

[Cancunbadlands]

It's been reported before

 

[SuperK401]

How hard do you swing your door open?

 

[garyp]

Most the time I don’t even open it all the way. Looking at it the metal is so thin you can see it flexing just moving the door. It needs to be reinforced in that area and the engineers have to know that. Why can they not do their jobs correctly yet still have a job

 

[Suzukiridr14]

22 xl drivers door spot welds hold the door stop arm broke loose. 28,000 miles. Never had any problems before. Further investigation looks like a really flimsy area. Not heard of anyone else having issues with this. Re welded it yesterday but the metal is really thin there. About 6-8 spot welds originally, all broken loose

WOW! never heard of that problem before, I would notify Ford about it.

 

[Glen Baker LLC]

It's a known problem on Ford Escapes which is basically the same platform for a lot of parts on our Mavericks. It is also happened on the mach e

 

[KO Stradivarius]

Looks like they didn’t fix the problem since the same episode with the 2020 escapes. Mine was recalled but the turds only replaced and reinforced the front doors hinges. I guess they figured the back doors didn’t get used as much so they could get away with doing only the fronts and hopefully the rears would’nt fail until after the warranty Had expired.

More likely there was an issue with the front door welding equipment settings that caused the bad welds, and the rear doors were OK. It doesn’t have to be a conspiracy.

They should be doing more frequent weld tear downs to catch this stuff.

 

[Scott Asheville]

I had a "snapping" sound on my driver's door when opened fully. I just stopped doing it, and now carefully open part way to the detents. I know that's not the right answer, so don't lecture me. Wind caught it yesterday and blew it full open - heard that snap.

One member here got that repaired. The Ford dealer tech warned him that would not be repaired free out of warranty, and that it's a dang expensive repair. But I don't intend to own my Maverick much longer.

So OP, it's a real problem. Probably the right answer is to complain and get it fixed before warranty expires. Probably the wrong answer is what I did - nothing.

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