Ford has a solution for the door cracks:
TSB 01-2-6 January 29,2001 (8 pages)
Article No. 01-2-6

Covers all 1997-2000 F-150 & 1997-1998 F250 LD

Procedure “A” – Door crack repair (less than 2” in length)
Procedure “B” – No door crack (preventive repair)
Procedure “C” – Cracks in door Panel (Longer than 2” in length)(requires replacement of outer door skin)

Procedure A & B require the use of repair kit # 1L3Z-15202W06-AA
Kit includes both ABS and Steel reinforcement blocks for the door and includes bonding adhesive.

Procedure C requires a new outer door skin and a new outer belt molding, as the old one will not fit on the new door skin. The ABS reinforcement blocks will not be required with the new door skin.

The local Ford dealer brought me 2 trucks to fix with this TSB in hand. The trucks waited at my shop for a week for the repair kits to get here, when it was determined that the kits would not be available till April. And they expect the demand for the kits to be high.
At least ford has admitted a problem with the door cracks and has put it in writing.
There is a link printed on the bottom of the TSB I have, but could not access it without fords dealer code and password.

I hope this helps those who have the ailment.

 

Kid over forty,
Your washers on in the mail.

:-) HJ

 

thank god. I was going to drop mine off about two months ago but I din't know what they where going to do to it.

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She has allot of toys on her.
MY BABIES STAT'S
Built 5/4/99
# 917 of 4000
2001 ET: 12.???, we'll find out soon.
When the green light drops, the bullsh*t stops.
MY ZING ALBUM: http://www.zing.com/album/?id=4293132307

 

How in the h*ll does the door "crack"? You guys must be slamming the crap out of it "to make sure it's shut". I only shut mine hard enough to get the latch to catch. Afterall, it can't crack just hanging there! It has to be because of slamming with the windows up and the blower motor running, thereby producing pressure at the weakest point or slamming with the window down and the top half of the door bending over against the soft rubber of the seal. It seems funny to me that the driver's door goes first. (Most use)

Again, how do you crack a door? Mine are perfect at 9k. I'm not trying to get flamed, I'm just wondering.

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Jim
Black '00
#1,757 built 3/30/00
Clear corners
J.L. Race program
J.L. Stage II ram-air
MagnaFlow Exhaust

 

Check the body forum. This has been discussed ad-nauseum

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GalaxyEng
2000 RED #2926
BedRug, Haig custom mats

 

Jim, it has NOTHING to do with slamming the door OR improper use of the windos/door. IF that were the case, all the doors on everyone's cars and trucks (that encounter this problem) would be cracked, don't ya think? No, I'm not slamming you. I'd love to hang out with ya sometime and have wings and beer since we live so close to each other

But seriously, it's been a problem with the 97 and up F150s and as I said in the other post, not all F150s are plagued by this problem.
Hopefully you're one of the lucky ones and don't have to have a skin changed or any paint work.

BTW, just let me know when is a good time for the wings and beer.

Trace

 

YOU ARE THE MAN! I think you just saved me the trouble/hassle of having a door that was painted a year after the original truck.

DUCK

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November 18, 1999 We will not forget.
The fallen 12 will live in our hearts forever.
Fightin' Texas Aggie Bonfire 1999

 

I don’t believe that the door cracks are as a result of improper use or slamming.
I have inspected 14 trucks with the cracked doors so far, all 14 have power windows, and only 2 have had cracks on the passenger side.
Ford’s TSB does not mention the cause for the cracks.
I believe it to be the use of the power windows. If you watch the outside door skin in the affected area when the window reaches the top, the skin is flexed outward before the motor stops.
The doors with the larger cracks it is really easy to see the metal move at the crack. The biggest cracked doors belong to smokers, probably opening and closing the window often for ventilation.
Just my observation.


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White '00 #1717
Muth Mirrors
Keyless entry
2" Rear Drop
Lighted Logos

 

Had mine fixed, cracked again, the dealer then replaced the door. Careful.... the door does not line up properly. There is nothing that can be done regarding. Every door is different.

 

Well, that makes sense. New, mine acted like the motor was over-traveling as well. It's not bad at all now. Who know's, maybe it's done all it's gonna do.

I was upset when I posted that about slamming - my wife slams the doors so hard in her van that the interior panel just broke loose the other day. She could tear up an anvil with a rubber mallet.



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Jim
Black '00
#1,757 built 3/30/00
Clear corners
J.L. Race program
J.L. Stage II ram-air
MagnaFlow Exhaust

 

I have a question for those who have had their door replaced.
Did the dealer replace the entire door shell? (Complete unit, inside and outside skin, pre assembled)
Or did the dealer just replace the outside “skin” of the door? (Out side panel is cut off of original shell. Edges of the new skin is folded over the original shell)
Ford’s TSB calls for a skin replacement only.
If you open the door and inspect the folded lip on the inside edge of the door, with a sharp eye, you should be able to see a difference from the passenger door if it wasn’t done. It is pretty tough to get that inside edge as smooth with a hammer as the factory does with their machines.

 

Mine has craked (56000KM),and I know it has nothing to do with power windows as my 98 does not have them.

 

My dealer has these kits in stock. Mine is to get done today.

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Andy Whittle
White 2000
#2482 of 4966
Built 4/27/00

My Autocross car

 

Thats Great!
I currently have 4 trucks on the list waiting for the dealer to get the kits in.
CB...
I wander if your door also flexes in this same area when the window tops out in the seal?

 

Just wondering where these cracks you guys are talking about. Top of the door, bottom, front, towards the rear? I'll look at mine tomorrow.