Proper Door Panel Alignment Issues?

[Melzingah]

Hello, total n00b here. I noticed my driver side door of my new 2024 Bronco Badlands has a gap that is larger on the top than the bottom between the door and front panels of the driver's side of the vehicle. And when I go to open the door the bottom of the door almost touches the bottom of the front fender.

The passenger side door doesn't have this same wide to narrow gap, the gap is equal all the way down.

And when you look at the other side of the driver door you can see the opposite, as if the door was aligned off-kilter. The top of the door almost pinches the rear fender.

So I asked my dealer about this and I was send some images from other 2024 models currently on the lot with the explanation that "it is designed this way for off-roading to allow the vehicle body to flex since most of the flexing would happen at the top of the vehicle" — which I don't fully understand.

Does this make sense to anyone? Would it be possible to explain this to someone as if I was a five year old?

Why would the driver door have this and not the passenger door?

Does your 2024 model look like this too?

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[Reidt131]

Hello, total n00b here. I noticed my driver side door of my new 2024 Bronco Badlands has a gap that is larger on the top than the bottom between the door and front panels of the driver's side of the vehicle. And when I go to open the door the bottom of the door almost touches the bottom of the front fender.

The passenger side door doesn't have this same wide to narrow gap, the gap is equal all the way down.

And when you look at the other side of the driver door you can see the opposite, as if the door was aligned off-kilter. The top of the door almost pinches the rear fender.

So I asked my dealer about this and I was send some images from other 2024 models currently on the lot with the explanation that "it is designed this way for off-roading to allow the vehicle body to flex since most of the flexing would happen at the top of the vehicle" — which I don't fully understand.

Does this make sense to anyone? Would it be possible to explain this to someone as if I was a five year old?

Why would the driver door have this and not the passenger door?

Does your 2024 model look like this too?

As per usual, this seems to be the dealer lying out of their a$$.

The vehicle will flex equally side to side, meaning the doors will experience both upward and downward deflection. However, there is no reason for the doors to be low at no flex.

It isn't super severe misalignment but if it bugs you, you deserve to have it fixed.

The doors should be adjusted to match the body lines and have equal panel gaps.

 

[Melzingah]

Thank you @Reidt131

 

[coverthawk]

I have a similar issue that I am in the process of having diagnosed now. 2024 Bronco Raptor, received a month ago, 300 miles. I had only been driving it (solo) to work, and last week I attempted to open my passenger front door and the dreaded CREAK noise. The front fender looks to be misaligned from the front door such that the door, when opened, is hitting/rubbing the fender. The dealer was AMAZING in that they took the car in, evaluated it, and I am now directed to a body shop for repair as they cannot affect repair themselves. The service manager spoke with me and even is allowing me to go to any body shop I find (as the one they use is backed up and he is wanting me to get this fixed as soon as possible). Was told to simply have the body shop I choose submit the invoice to him directly or if needed they will even use a credit card to pay the body shop and they will work with Ford for the service order. So far I am MOST impressed with how my dealership is handling this...let's see how the fix is implemented...

 

[Melzingah]

@coverthawk best of luck to you. Do you have any photos you could share so I can add them to my report to Ford?

 

[coverthawk]

@coverthawk best of luck to you. Do you have any photos you could share so I can add them to my report to Ford?

I am sorry - I do not. I attempted to take pictures before bringing to the dealership, and they came out terrible (not showing misalignment - black color. I also don't want to open the door to show the impacted area as it is damaging the paint on both the door and fender...if I can get some better pictures I will send to you.

 

[MichaelCar001]

To adjust the door alignment, start by loosening the hinge bolts just a bit, but don't take them all the way out. You might also need to reach the bolts on the A-pillar. Adjust the door by moving it up, down, forward, or backward until it lines up correctly. If needed, use a rubber mallet to gently tap the door into place. Once everything looks good, tighten all the hinge bolts.

 

[MannyG20]

Looks like it was put together at the Tesla factory.

 

[Melzingah]

To adjust the door alignment, start by loosening the hinge bolts just a bit, but don't take them all the way out. You might also need to reach the bolts on the A-pillar. Adjust the door by moving it up, down, forward, or backward until it lines up correctly. If needed, use a rubber mallet to gently tap the door into place. Once everything looks good, tighten all the hinge bolts.

Great advice, do you think that doing this also helps the pitch or door? My concern is the hinges may not be aligned properly.

 

[Melzingah]

I am sorry - I do not. I attempted to take pictures before bringing to the dealership, and they came out terrible (not showing misalignment - black color. I also don't want to open the door to show the impacted area as it is damaging the paint on both the door and fender...if I can get some better pictures I will send to you.

That would be amazing, thank you. The more examples I can find the more of a case I can make to get this fixed for others. I love this community!

 

[frdfan]

@coverthawk best of luck to you. Do you have any photos you could share so I can add them to my report to Ford?

Ford (Corporate) isn't going to do anything except refer you back to the dealer. Best advice I can give is--physically go into the dealership and speak with the service manager or in this case, body shop manager. hell, get your salesperson involved...if nobody at that point wants to help, get the GM of the dealership involved (they hate customer issues getting to their level). An in person visit means they can't placate you with "all the others are like this..or it's designed this way". This should have been caught in the PDI.

 

[Jhebs]

2024 Badlands. I was at the dealership last week for this issue. I wanted the door aligned before the paint got damaged. The door hinges have adjustment in them, however the striker does not. Needless to say i was back at the dealership this morning because i now have paint damage and I've only got 2,000 miles on the thing.

 

[flip]

2024 Badlands. I was at the dealership last week for this issue. I wanted the door aligned before the paint got damaged. The door hinges have adjustment in them, however the striker does not. Needless to say i was back at the dealership this morning because i now have paint damage and I've only got 2,000 miles on the thing.

The plant has a tool to do this adjustment, kinda similar to this one but on a 4 foot bar. That said, adjusting these is not very difficult and sounds like dealer just doesn't want to mess with it.

 

[flip]

Front Door Alignment
Inspection

NOTE: Removal steps in this procedure may contain installation details.

NOTE: LH side shown, RH side similar.

1. Inspect the front door-to-body dimensions.

Adjustment

All alignments

1. Open the door.

1. Remove the bolts and the striker assembly.

Front door in and out, up and down alignment

1. Loosen the bolts to permit movement of the door.
   Loosen:
   : 2 turn(s)

1. Adjust the door as required.

1. Tighten the bolts.
   Torque: 41 lb.ft (55 Nm)

Front door fore, aft and tilt alignment

1. Loosen the bolts to permit movement of the door.
   Loosen:
   : 2 turn(s)

1. Carefully close the door.

1. Adjust the door as required.

1. Carefully open the door.

1. Tighten the bolts.
   Torque: 24 lb.ft (32 Nm)

All alignments

1. Install the striker assembly.
   Torque: 18 lb.ft (25 Nm)

1. Loosen the bolts to permit movement of the striker assembly.
   Loosen:
   : 2 turn(s)

1. Tighten the bolts.
   Torque: 18 lb.ft (25 Nm)

1. Inspect the body-to-front door dimensions.

 

[Jhebs]

Front Door Alignment
Inspection

NOTE: Removal steps in this procedure may contain installation details.

NOTE: LH side shown, RH side similar.

1. Inspect the front door-to-body dimensions.

Adjustment

All alignments

1. Open the door.

1. Remove the bolts and the striker assembly.

Front door in and out, up and down alignment

1. Loosen the bolts to permit movement of the door.
   Loosen:
   : 2 turn(s)

1. Adjust the door as required.

1. Tighten the bolts.
   Torque: 41 lb.ft (55 Nm)

Front door fore, aft and tilt alignment

1. Loosen the bolts to permit movement of the door.
   Loosen:
   : 2 turn(s)

1. Carefully close the door.

1. Adjust the door as required.

1. Carefully open the door.

1. Tighten the bolts.
   Torque: 24 lb.ft (32 Nm)

All alignments

1. Install the striker assembly.
   Torque: 18 lb.ft (25 Nm)

1. Loosen the bolts to permit movement of the striker assembly.
   Loosen:
   : 2 turn(s)

1. Tighten the bolts.
   Torque: 18 lb.ft (25 Nm)

1. Inspect the body-to-front door dimensions.

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