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Hinge Adjustment - Sliding Door

WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: For correct sliding door operation, it is critical that the door adjuster wedge and striker on the body pillar fit smoothly into the wedge pocket and latch in the power sliding door. If any of the following adjustments are made, realignment of the striker may be necessary.
NOTE: Never use a wedge to adjust or fit the sliding door. Using a wedge to force the door to move will cause the wedges to squeak and eventually break. It will also cause a power sliding door to reverse prior to full closure or not close completely.
NOTE: Never use the strikers to adjust the door. It will cause a rattle or affect door opening or closing efforts.
    NOTE: Flushness is the inset or outset alignment of the panels to each other.
    Fig 1: Checking Sliding Door Flushness
    G03246587Courtesy of FORD MOTOR CO.
  1. Measure the door flushness.
    • Inspect the sliding door.
    • Measure the door flushness according to the following specifications:
    SLIDING DOOR FLUSHNESS SPECIFICATIONS

    Item Location Flushness
    1 Front door to fender -2.0 - 2.0mm (-0.08 - 0.08 inch)
    2 Sliding door to front door -2.0 - 2.0mm (-0.08 - 0.08 inch)
    3 Manual sliding door to quarter panel -3.0 - 3.0mm (-0.12 - 0.12 inch)
    4 Power sliding door to quarter panel -3.0 - 3.0mm (-0.12 - 0.12 inch)
    2. NOTE: If the upper and lower wedges are not loosened, it will pull the sliding door into the same position the door was in before the adjustment. The wedges should be loosened enough to move, but not so loose that they cannot hold their position when moved.
    Fig 2: Loosening Upper And Lower Wedges
    G03246588Courtesy of FORD MOTOR CO.
    NOTE: The B-pillar wire striker should be centered in the catch assembly opening. Do not use the B-pillar wire striker to position the door.
    Inspect the alignment of the B-pillar wire striker in the catch. If the striker is not centered, proceed as follows:
    Fig 3: Centering B-Pillar Striker
    G03246589Courtesy of FORD MOTOR CO.
    NOTE: The C-pillar striker should be centered in the latch assembly opening. Do not use the C-pillar striker to position the door in an up or down direction.
    Inspect the alignment of the C-pillar wire striker in the latch. If striker is not centered, proceed as follows:
    Fig 4: Centering C-Pillar Striker
    G03246590Courtesy of FORD MOTOR CO.
    NOTE: The vehicle may be equipped with either an M6 or M8 size bolt at this location.
    If the lower front portion of the sliding door does not meet the sliding door to front door flushness specification, proceed as follows:
    Fig 5: Adjusting Lower Roller
    G03246591Courtesy of FORD MOTOR CO.
  2. Loosen the screws.
    • Mark the edges of the striker.
    • Slightly loosen the screws.
    • Tap the striker into the correct position.
    • Tighten the screws.
    • Mark the edges of the striker.
    • Slightly loosen the screws.
    • Tap the striker into the correct position.
    • Tighten the screws.
    • Loosen the lower roller bolt.
    • Move the bracket until the lower portion of the sliding door is flush with the lower portion of the front door.
    • Tighten the M6 size lower roller bolt to 12 Nm (9lb-ft) or the M8 size bolt to 20 Nm (15 lb-ft).
  3. If the upper front portion of the sliding door does not meet the sliding door to front door flushness specification or if the sliding door to quarter panel does not meet specification, proceed as follows:
    • Mark the forward and rearward edges of the bracket.
    • Loosen the upper roller nuts.
    • Move the sliding door to gain flushness specification.
    • Tighten the nuts.
    Fig 6: Adjusting Upper Roller
    G03246592Courtesy of FORD MOTOR CO.
  4. The B-pillar and C-pillar wire strikers should be centered after steps 5 and six 6 completed. For further adjustment, refer to steps 3 and 4.
    5. NOTE: The margin is the gap between two adjoining panels.
    Fig 7: Identifying Door Margins
    G03246593Courtesy of FORD MOTOR CO.
  5. Inspect the sliding door. Measure the margins of the sliding door according to the following specifications:
    SLIDING DOOR MARGIN SPECIFICATIONS

    Item Description Measurement
    1 Sliding door to roof 3 - 7mm (0.118 - 0.275 inch)
    2 Sliding door to quarter panel 3 - 7mm (0.118 - 0.275 inch)
    3 Sliding door to front door 4 -8mm (0.16 - 0.314 inch)
    4 Sliding door to rocker panel 4 - 6mm (0.15 -0.24 inch)
    5 Front door to rocker panel 4 - 6mm (0.15 -0.24 inch)
    6 Front door to fender 3.0 - 6.0mm (0.12 - 0.23 inch)
    7 Front door to A-pillar 4 - 6mm (0.15 - 0.24 inch)
    8 Front door to roof 3 - 7mm (0.118 - 0.275 inch)
  6. If the sliding door to front door margin does not meet specifications or if the door requires horizontal or vertical adjustment, adjust the lower roller bracket as follows:
    1. Remove the bolt plug cover from the lower corner of the sliding door trim panel.
    2. Mark the door around the lower roller bracket to measure the adjustment increments.
      3. NOTE: The lower roller bracket and guide assembly bolts should be loosened enough to allow the assembly to move, but not so loose that the assembly cannot hold its position when moved.
    3. Loosen the lower roller bolts.
    4. Use a nylon hammer to adjust the hinge up or down. Make sure that the front door margin is equal and within specification at the top and bottom.
    5. Close the sliding door and check for correct fit. Readjust if necessary.
    6. Tighten the bolts.
    7. Install the bolt plug cover.
    Fig 8: Adjusting Lower Roller Bracket
    G03246594Courtesy of FORD MOTOR CO.
  7. If the sliding door to quarter panel does not meet specifications or if the door requires horizontal or vertical adjustment, adjust the sliding door center roller hinge as follows:
    1. Remove the center roller hinge nut.
    2. Lift the rear of the door to separate the center roller hinge bracket from the center roller hinge mount bracket.
      3. CAUTION: Do not swing the door open more than twenty-five degrees or damage to the other hinges may occur.
    3. Swing the door open and support if necessary.
    4. Mark the edges of the center roller hinge mount bracket.
    5. Slightly loosen the bolts.
    6. Re-attach the center roller hinge bracket.
    7. Tap the center roller hinge into the correct position.
    8. Separate the center roller hinge bracket from the center roller hinge mount bracket and tighten the bolts.
    9. Re-attach the center roller hinge bracket to the center roller hinge mount bracket.
    10. Install the nut.
    11. Close the door and check the alignment.
      Fig 9: Adjusting Center Roller Hinge
      G03246595Courtesy of FORD MOTOR CO.
    8. NOTE: The B-pillar and C-pillar wire strikers should be centered after steps nine and ten. For further adjustments, refer to steps three and four.
    NOTE: Make sure the screws are loosened.
    Fig 10: Adjusting Upper And Lower Wedges Screws
    G03246596Courtesy of FORD MOTOR CO.
  8. Adjust the upper and lower wedges.
    1. Close the sliding door.
    2. Open the sliding door.
    3. Check for correct male to female wedge alignment.
    4. Gently tap the male wedge into place if necessary.
    5. Tighten the screws.
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