'05 FX4 FS SCAB Black - 109K miles. My door is broken at the lower hinge. I think this may have been caused by the failure of the little plastic mechanism that stops the door when full open to prevent it from hitting the hinge at the cab side. Door sheet metal is actually broken at top and bottom of hinge. Ford dealer body shop mechanic said he had never seen something like this happen before. Anyway - way out of warranty and although I am a long time Ford customer (I have bought 8 new Ford vehicles thru the years) they didn't want to help me with any of the repair/replace cost.

So I found a used door online. I would like to attach some pics of the broken door but I can't figure how to do that yet.

I have a nice white door from a '06 (looks like XLT) - so I need to disassemble this new door before repaint to black.

Any advice from someone who has done such a project would be appreciated. I have the Ford shop manuals and they are essentially useless for this work. Pics, tips, and instructions much appreciated.

 

Welcome from SoCal. I beleive complete removal for the front fender is required to get full access to all the bolts on the hinges. If you're going to do a true repaint of the new door, strip the door of all mouldings, wire looms, lock mechanisms and the glass. I would remove all of the parts you want to salvage on the old door while the door is on the truck first. Pay close attention to the wire harness since all of your cab accessories are run through that door and will be critical to the reassembly. Take lots of pictures as you go for reference when you reassemble the door. Good luck