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Any alternative fixes for broken door check strap weld?

44339 Views 16 Replies 10 Participants Last post by  junglebunn
I've got the dreaded door check strap weld that broke after the warranty for it expired. I'm not paying ~$1k for a repair that might fail again or $2k to get the entire door replaced with the new bolt style plate.

So I'm wondering if any of you have tried some alternative method of fixing it that doesn't require taking the entire door apart. In my particular situation, only the bottom weld broke, so the cup flops around making banging sounds each time the door check strap decides to pop in or out. I'm thinking maybe a strong epoxy or even superglue might be able to grip that bottom piece of metal well enough to make a good fix. Since the only pressure pulling apart the glue would be the door check strap pressing in, maybe the glue is enough.

Has anyone tried this as a fix? Any reason you think this would not work?

I've gotten so used to and annoyed with the sound of the drivers door pop, that when I enter the passenger side the rare times I do, it feels so good to open a door and hear nothing and feel no ridiculous resistance. I really want to get the drivers side fixed, I wish toyota wouldn't have set such a low time limit on this warranty. These things don't break on any other car I've ever seen.
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I measured the opening in the door and the approximate angle of the mounting surface of the check strap base, I welded up an externally mounted plate and cup that fits on the door and bolted it with round head machine screws to the door. I had also broken out the remaining pieces of the broken cracked original mount. Now I have a very sturdy fix, which of course can be seen when the door is open, but no more creaking and cracking. I did this on my 2006 tundra, the same problems and door weakness of the Sienna, which my wife has and also now needs the same repair. Seems a company could commercially make this external insert and make some decent money.
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