Thanks for the thread!
I use my XJ for fishing trips, and winter driving. I just got in on the road for the winter here in Minnesota after not having driven it all summer, and noticed the sagging door that I had forgotten about.
Now that I think about it, I remember when it is -30F here, supercooled air comes in through the crack and freezes my left shoulder and elbow!
It's the beginning of December now, and I feel I'm running out of time. I just replaced the cooling system, which was my highest priority...can't decide if I'll do this repair, or just use the passenger door until spring!
Chrysler's decision to weld the hinge to the sheet metal reminds me of another poor decision to weld to the unibody--I remember having to bust off some nuts on the top rear shock mounts that were tacked to the sheet metal, and replacing them with nuts and bolts with the bolts facing downward.
BTW, thanks for this forum--my cooling system replacement went great and thanks to the info from this forum, the Jeep is running at perfect temperature...haven't seen that performance in 2 or 3 years! I burped it and everything.
Thanks again.