Fasttimez

I hate to be the bearer of bad news, but it's NOT the doors, it's the cab that's the issue. My local dealer has tried to fix my buddies truck about 5 times before sending it off to an independent body shop. They tried to get the original doors to align with no luck. Then they took doors off another F150 on the dealer lot that was perfectly aligned to it's truck & they still wouldn't line up. Finally they found the actual cab was the problem, it was slightly distorted. They found this by comparing measurements from other F150 cabs on the dealer lot. When Ford was shown all the evidence, they acted as if they already knew about this problem (kinda weird). They then agreed to swap out his truck for another of equal value on the dealer lot & took the truck back. This was just a little over a week ago. So have somebody check your cab, NOT the doors. It's pretty simple when you think about it now, what are the chances you have 2 or 3 doors that don't align properly & the problem is with all the doors. The thing all the doors have in common is the cab that's slightly distorted causing the misalignment of the doors.

Spamfritter

This makes a lot of sense to me.

Ohsix

My 16 SCAB had a large gap between fount and rear doors I installed two washers between hinge and door now the gap is correct
Later I'll remove panels behind rear seat to adjust hinge
I drove my truck down a very bumpy road to get the Cab to settle in

carrierj

Excellent idea to take the initiative and fix this yourself. However, be sure that the washers you used are aluminum or another acceptable Isolator. See the below bulletin.

https://www.fleet.ford.com/truckbbas/non-html/Q-222.pdf

Ifallsguy

If the dealer really has had your truck in the shop for more than 30 days, check your state Lemon Law. Most give a max of 30 days in 12 months to call the vehicle legally a lemon and give you the right for a refund or replacement vehicle.

Ohsix

After the weather gets a little cooler I'll remove the staniless washers and remove panel to adjust

SeatGuru

Just going to throw this out there but you have dissimilar metals in contact with each other. Yes there is paint there but still...

There is a reason that Ford includes plastic barrier tape on the mud flap kits to isolate the stainless bracket and the aluminum body.

Ohsix

I installed two 18-8 Stainless washers
I will remove the washers in a few Days wipe off the Nickel anti-seize and
Put them in the washer can
The STEEL that FORD used for the hinge will then again be
Tightened against the Door Panel that is as you may know Is Aluminum

kendive

Or thousands with the problem and don't say anything... LOL

I have most of my noise issues fixed by adding seals but you should not have to do that and I don't feel like dealing with Ford and the dealer to fix when I have heard cases of them making matters worse.





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Spamfritter

My truck isn't perfect, but it doesn't have door alignment or cabin noise problems. As I've said before, even if these problems seem common on the forums, that's not necessarily an indication that these issues are widespread.