Originally Posted by Luckyontheducky
I have a '97 with a worn lower door hinge bushing that makes closing the door a real chore. Dealer says it only makes sense to replace both hinges. Visually, the top hinge is fine, and the bushing on the lower is all torn up. As you have to take the dashboard out to get to the top hinge, its a $1000 job. Has anyone had this problem, or replaced the lower hinge before? I had a Mustang ('79) with the same problem. I guess Ford never got doors figured out. This vehicle will be for sale in Jan/Feb timeframe if anyone is interested in a V8 in good condition.
Long Island, NY
Quick fix: with a helper holding the (darn heavy) door, loosen the screws attaching the lower hinge to the door (NOT TO THE BODY!!), then stick some aluminum foil (folded multiple times to make for a 2-3 mm spacer plate) between the door and the hinge, right between the screws. Tighten the screws, and drive happily everafter. It worked great on my previous Cougar - just make sure that the aluminum spacer is wide enough so that the hinge is well supported.