Front Door - Sagging
NO: 23-66-94GROUP: Body
DATE: Sep. 16, 1994
SUBJECT:
Front Door Forward Hem Separation
MODELS:
1991 - 1995 (AS) Town & Country/Caravan/Voyager
1991 - 1995 (ES) Chrysler Voyager (European Market)
SYMPTOM/CONDITION:
Separation of the front door forward hem may result in a door "sag" complaint. Separation of the front door forward hem is usually caused by repeated hard opening of the door against the door check.
DIAGNOSIS:
Open the door to its limit of travel. Apply slight pressure against the door check while observing the front door forward hem. If there is any relative movement between the inner and outer door panel hem, perform the repair procedure.
REPAIR PROCEDURE:
NOTE:
THIS REPAIR SHOULD BE PERFORMED BY A QUALIFIED BODY REPAIR TECHNICIAN.
This bulletin involves welding the inner door panel to the outer door panel along the front door forward hem.
1. Confirm alignment is correct of the door-latch to the latch-striker. The door will fall off the latch-striker when the door is opened if the door-latch is low to the latch-striker and a door sag condition exists. If the door-latch is low to the latch-striker, proceed to step 2, otherwise continue the repair procedure with step 3.
2. With the front door opened to its limit of travel, position a floor jack at the rear of the door. Place a soft block on the load bearing portion of the jack to prevent any marring or distortion of the door. Raise the jack until the soft block contacts lower wide flat portion of the door. Continue to raise the jack until the front door forward hem separation is closed. Keep the floor jack in this position until the welding operation is complete.
3. Position a welding blanket so the interior of the vehicle is protected from welding sparks. Position another welding blanket so the door trim panel is protected from welding sparks.
4. Clean and prepare surface and make 5 MIG welds in the locations shown in the illustration. Each weld should be 1/4 in. (6 mm) in length and follow the inside flange edge of the hem. Each weld should be applied using multiple short length of time arcs to minimize the amount of heat build-up that may have a negative effect on the show surface of the outer panel.
5. Remove the floor jack from under the door, if necessary.
6. Verify proper door alignment, adjust as necessary.
7. Refinish and paint the door in the areas of welding as necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-00-10-92 Right Or Left Side 0.8 Hrs.
23-70-03-90 Refinish 1.0 Hrs.
MATERIAL ALLOWANCE $11.59
FAILURE CODE: 7X - Weld Defect