Just noticed recently that my door was not closing properly, as indicated by the wind noise coming from the window frame. I was inspecting it to see if I could figure out why my door was not shutting all the way and noticed that the hinge weld was breaking/ripping away from the frame. What can I do at this point, can I reweld it, is there any way to reinforce it, what are my options? I noticed that the passenger door is doing it as well, just not as bad. I was thinking of removing the doors and going with tube doors, but at a later time when I had the seats and floor a little more waterproof.

 

Very common problem. You can probably weld it up easily as long as the sheet metal around it is good and you're good with a welder. I did my passenger side that way, and a body shop used different hinges on my driver's door. Now the ds door leaks and sits away from the body by about 1/4"-3/8" and howls like a banshee down the interstate.

 

There's a TSB on this issue for the '93-'97 years (PDF File):
Chrystler Bulletin 23-017-02

 

Link doesn't work.

 

Worked for me.

 

I have a 91 that the upper hinge on the driver's side broke off completely. I removed the fender, closed the door, and pulled it into place with a couple of ratchet straps to hold it in alignment.

Once everything was in place, I welded it back on with a mig gun. There were a few spots where I had to use filler plate because the gap was too large.

After you get the three sides welded, you can open the door to run a bead along the inside seam.

After repairing it, get it the habit of opening your door gently and not letting it slam against the stop (which is the reason it fatigues and breaks).

 

Mine is doing the same thing. Has been for years though, mine isn't bad enough for the doors to sag yet. My Cherokee is a 2 door by the way and I understand that this happens to all 2 door models at some point.

 

The link worked for me. Will the dealer still do this for you after 16 years?

 

^^ i dont think so.
but its worth looking into and getting back to us.

cuz if theyll do it ill let em !

 

I just spoke to the Jeep dealer in Indy and he referred me to a body shop that they use for this kind of thing. The body shop says they will do it and asked that I send them the .pdf copy of the Service Bulletin, which I did. And he further told me he would have to look at my XJ to give me an estimate on how much it would cost to do the work.

 

I had to say it works! I ordered part number 05083061AA online and completed section B of the PDF and it works like a charm. Used self tapping sheet metal screws instead of excessively large rivets to connect to body. It's been over a year and it works fine. Click the link for the PDF

http://go.jeep-xj.info/DoorHingeRepair.pdf

or cut and paste in your broswer to get to it

Print it out! No instructions come with part.
Top hinge was bad on mine. Didn't even have to take door totally off. Works great now.

 

Where did you order that part? I've been searching the world for that part number, and can't find it anywhere.