After checking out the driver door striker to see why the door is hard to close, I noticed that there was a bit more metal wear than on the passenger side. I suppose the door could be misaligned, but I didn't see any unusual deviations in the door/fender gap. I'm thinking about re-adjusting the striker but wanted to know if anyone had any tips for doing this. The FSM says it can be adjusted up/down and left/right by loosening the two bolts, and then tightening the bolts to 18 ft-lb.

 

If it's an alignment problem, why don't you take it back to the dealer and have them fix it? Especially if there is metal wear.

 

Well, it's because I want the problem fixed.

 

That sounds like me too. You are starting to scare me.

 

One of the striker bolts stripped out (torx screw). It didn't just strip out, instead ALL of the star edges cracked right off and fell onto the ground or the carpeting. Ford must have gone to the lowest bidder for these Chinese steel/aluminum screws.

The door still doesn't close properly. It won't close on its own weight if I open it FULLY and let it close by itself. It requires additional force to make it shut properly and overall I'm disappointed that no one at the factory caught onto this problem. It's either "normal", or I'm spoiled silly by the doors on the Crown Vic and the E-250 (tap.... clicks shut and you're done).

 

That is totally not normal. Get off your high horse and take it to the dealer. You already stripped out a bolt. That's why you have a warranty.

 

Yep, 'nuff said...... BTW, if you spec'd the 18 ft. lbs. of torque for the door striker bolts, how much pressure did you put on them to break the teeth of the torx head, and did you even have the right size wrench head?

 

What?
The FSM spec is 18 ft-lb. What I experienced trying to remove the bolt using a 3/8" ratchet with the correct bit was significantly more than 18 ft-lb. 18 ft-lb is what you normally use for the front cover studs/bolts (18-22 ft-lb) which is nothing to write home about with a 3/8" ratchet. I was afraid the torx bit I used was going to give, but instead I was "welcomed" with a splash of broken torx "teeth" splattering out from the cheap Chinese steel bolt. I did loosen the lower bolt w/o too much drama.

 

Oops..... Just take it in and fix it under warranty. It shouldn't be rocket science for anyone in service, and hopefully they don't give you too much of a ration for trying it yourself.