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Re: Adjusting front door sag[900/91] posted by Jim Bowers on
Monday, 26 June 2000, at 10:32 a.m.
The part of the hinge attached to the body can be moved to effect the changes you need. Take off the cover in the foot well to gain access to the bolts that hold that end of the hinge. Loosen all the bolts and you will be able to move the hinge end to align the door. Tighten the bolts gently and test the alignment. In a couple trys you should be able to get it almost perfect. Once you have it the way you want it, fully tighten the bolts.
Thinking about it some more, maybe the upper hinge is the problem. For that you need to get access behind the lower part of the dash. Remove the panel above your feet to get to those bolts. Maybe those have loosened to cause your original problem?
Bottom line, the hinge ends use clamp plates opposite the hinges and have large holes in the panels allowing all the adjustment needed. With a little patience you should be able to get a perfect fitting door that closes easily and yet seals tight.
--Jim Bowers, North of Boston, 96 965 w/70K, Had a '85 745 Turbo diesel for 200K