Apparently uncommon?

Jaime Diagnostician Florida Posted   Latest   Edited  
Case Study
Collision
2018 Ford Edge Titanium 2.0L (9) 6-spd (6F)
Noises While Operating Exterior Doors

My wife's 2018 Ford Edge, bought new, recently developed a snapping/creaking noise when one operates the driver's door. I (re) lubed the hinges and check-link without resolving the “customer” complaint. Because I have experience with some fine German engineering that exhibited the same symptoms I ordered Ford replacement check-links (they were surprisingly inexpensive unless purchasing directly from a dealer).

I replaced it without much effort (thank you Ford Engineers) but the noise wasn't affected in the least. Looking closer I found the bracket inside the door through which the check-link passes, has 4 (FOUR) spot welds on the inboard side, but only 2 (TWO) on the outboard side. One of the two spot welds had broken from the skin of the door (thank you AGAIN Ford Engineers), leaving only one to support the load when the door was operated. See pictures.

I'm of the belief our warranty has expired for such a fault so I'll likely repair this engineering defect myself. A search here, and throughout the web indicated Ford believes noises such as I described are caused by door trim push buttons but, sorry to say (and to show), they're ignoring reality.

I intend to drill out the two spot welds and replace them with threaded fasteners, maybe adding a wider surface area through which they'll pass (like a large diameter flat washer), and secure them inside the door with lock washers and nuts.

HTH

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Interesting
Brandon Manager
California
Brandon
 

Mid 2000 Subarus commonly had a similar problem with spot welds on the door brace. The best fix is to drill and rivet the metal together.

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Jaime Diagnostician
Florida
Jaime
 

Thanks Brandon! I considered doing so - but do not have the room for my riveter to fit inside the door and I really don't want to unhinge it for this task to rivet it in the other direction.

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Glen Owner/Technician
Illinois
Glen
 

Why the rust around the broken spot weld?

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Frank Owner/Technician
Ontario
Frank
 

I would guess the contact/rubbing of the 2 ‘pieces’. Where there's rust look for it to not be fixed in place.

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Jaime Diagnostician
Florida
Jaime
 

Frank, I'd agree if there was rust evident inside the door. As you can see, it's pristine.

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Jeff Technician
California
Jeff
 

Florida humidity

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Jaime Diagnostician
Florida
Jaime
 

It rains in Florida almost daily. Since the noise started over a month ago, I believe the rust is where the spot weld and the sheet metal scrape against each other.

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Derek Educator
Virginia
Derek
 

Any time you see that bright red new rust, that means something is moving, and failing as something is rubbing off the old rust to make new rust.

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Glen Owner/Technician
Illinois
Glen
 

Good to know, Thanks!

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Obie Technician
Washington
Obie
 

If they admit a problem they might have to fix millions of them. So yes, a very unusual problem.

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Jaime Diagnostician
Florida
Jaime
 

I agree Obie. Having worked several years in a dealership, I remember how “creative” the warranty clerk's descriptions could be.

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Dan Owner/Technician
Texas
Dan
 

…Jaime… I would think that pop rivets with additional washers on the inside would be an effective and quick fix for this problem…Dan .

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Glen Owner/Technician
Illinois
Glen
 

What about glass stop rivets?

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Dan Owner/Technician
Texas
Dan
 

…Explain “glass stop” please…Dan .

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Glen Owner/Technician
Illinois
Glen
 

The ones that peel on the backside like the ones that Ford uses on door actuators.

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Jaime Diagnostician
Florida
Jaime
 

Glen, I wondered too (thanks for the explanation). Please see my other replies about using rivets.

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Jaime Diagnostician
Florida
Jaime
 

Hi Dan! I considered doing so - but do not have the room for my riveter to fit inside the door and I really don't want to unhinge it for this task to rivet it in the other direction. I only have a ¼" rivet gun I got back in ‘92 when I started having to replace Crown Vic/Grand Marquis door window regulators all day long. LOL. I won’t buy an angled gun now that I'm "retired".

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Paul Mechanic
Illinois
Paul
 

I would just grind down the original weld and hit it with a mig welder while forcing panels together. You don't really drill out a spot weld, you remove the metal around it. I feel your making a lot of unnecessary work for yourself as your going to have to do a little refinishing on jamb to prevent corrosion anyway. If you don't have a welder handy- pop rivets around the same area will work. I…

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Jaime Diagnostician
Florida
Jaime
 

Hi Paul! Thanks for the “kudos”. My feelings: If the original spot weld failed, installed when the metal was not painted, I doubt another one (or even one running the length of the bracket) would last either. Add the additional sanding and painting on top of that and I'm REALLY not sold on that idea. However, if I spread the load across several square inches of the door skin surface using a 2"…

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Paul Mechanic
Illinois
Paul
 

Maybe check a few of the same models if you see any and check their condition. Perhaps your vehicle is only one of the"lucky" ones? Is it possible the door was over extended during an opening event, i.e., wind pulled it open by accident causing it to flex? It really may be an isolated occurrence.

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Rolando Diagnostician
Texas
Rolando
 

You should check your warranty. Most manufacturers carry a rust perforation warranty this might fall under separate from new car warranty. I've seem some rust warranties of at least 8 years or more. Seems kinda odd for a car this new to be rusting like that unless it wasn't properly coated from the factory with primer and paint. Now if body work was done in the area that would be a different…

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Paul Mechanic
Illinois
Paul
 

I think the rust arose after the weld popped and exposed the edges.

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Jaime Diagnostician
Florida
Jaime
 

I agree Paul.

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Jaime Diagnostician
Florida
Jaime
 

Thanks Rolondo! I hadn't considered that angle. I too feel it strange that a car this new, and well-cared for, would have such a problem. BTW, no body work's been done to the car anywhere.

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Eric Owner/Technician
Wisconsin
Eric
 

I've repaired this type of failure many times over the years. When I had a spot welder that was my favorite way to fix them, limited damage and easily covered with a quick spray of paint. Since I sold my spot welder (no longer doing body work) I have found the longest lasting fix is to drill the spot welds out and use bolts, washers and lock nuts to hold everything back together. I use…

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Jaime Diagnostician
Florida
Jaime
   

Eric, exactly my intentions, each step of the way, except for the spot welds. I think if the original ones pulled from the door skin then any new ones would do so too. If I had a spot welder I'd add a plate to the outer door skin, sandwiching the door skin between the inner bracket and the plate. I think that'd last but I'd still have a lot of prep/painting to do using this method. SS screws…

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Jaime Diagnostician
Florida
Jaime
 

Update: My curiosity got the better of me and I wondered, how's the passenger side look? I'll try to get a picture or two but on that side, BOTH welds have broken! The whole door skin flexes wildly when I swing it to it's stop. I'm going to buy a 72 hour sub to the Ford Information site later (since Identifix is WORTHLESS for TSBs - and shows NO recalls ever for this vehicle, which is…

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Dwight Owner/Technician
California
Dwight
 

You can also search here for vehicle recalls. And it's free. nhtsa​.​gov/recalls

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Jaime Diagnostician
Florida
Jaime
 

Great resource! I heard the door latches might be recalled but didn't think door check spot welds was something Ford would voluntarily offer to fix (and since they're not safety related, don't think NHTSA would force it). I'll look though. Thanks!

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Jaime Diagnostician
Florida
Jaime
 

My local Ford dealership said it'll be 8 weeks (?!!!?) before they'll be able to begin work on the vehicle, if I "approve the estimate". Apparently, since the sheet metal isn't suffering from their definition of “Rust Through” to cover it under that warranty (separate from the other warranties), in other words, the paint's not bubbling from underneath and the inside of the door is pristine, Ford…

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