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Has anybody had to have a door replaced?

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by cabillings, Jun 16, 2008.

  1. cabillings

    cabillings New Member

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    My neighbor backed into my Prius right between the driver's door and left fender, so both needed to be replaced. The first door came in and was all painted and put back together when I noticed that there was some raw metal where the bottom of the door meets the window frame part. Some caulking was missing. Then we noticed that all of the caulking is missing on the entire door. The guy at the body shop (which I will tell you about after the car is done) says that Toyota missed a step in manufacturing. The caulking is perfect, so it's obviously done by a robot. So, they ordered another door and the same thing...no caulking. He calls Toyota and for some reason the local Toyota dealer says that they all come that way. I can't imagine Toyota sending doors that are incomplete. Does anybody know is this is fact, or BS?

    Thanks!
     
  2. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Hi Chris,

    I am unfamiliar with the issue that you raised. Would you mind taking a photo of the new driver's door as well as a photo of the existing passenger-side door, and explain the differences that you noticed.
    Thanks!
     
  3. Bill Merchant

    Bill Merchant absit invidia

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    I'm confused too, Chris:
    I can't picture the bottom of the door (nearest the ground) in relation to the window frame (on the upper side of the door, away from the ground). Which part, where?
    [​IMG]
     
  4. cabillings

    cabillings New Member

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    Here's the top corner of the door. Left no caulking (new door), right with caulking.
     

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  5. cabillings

    cabillings New Member

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    Here's where the bottom of the door meets the window frame. Left no caulking (new door), right with caulking.
     

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  6. cabillings

    cabillings New Member

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    Here's the bottom of the door. Left has no caulking (new door), right with caulking.

    As you can see from the pictures, there's caulking all over the door on the original, but not on the new door. What do you think?
     

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  7. ZC1

    ZC1 Junior Prius Owner

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    Weird, why the caulking is clearly missing.
    I wonder if it's really some aftermarket door.

    If it's a true Toyota replacement door, then what does the dealer's body shop do with a door such as this, simply install it?

    At the very least I would have the body shop apply some type of caulking to these seams.

    ZC1
     
  8. cabillings

    cabillings New Member

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    The work is being done at a non-Toyota body shop in Long Beach. However, it is a certified car dealership. The Toyota dealer in the area recommends this body shop and so does my insurance company. I'm suppose to go back there to see what they have done with a new door to see if it's acceptable. I don't think that anybody can caulk like a robot. I just want my car back the way it was brought in but without the big dent in the side. This will be the third time that I leave it there. Each time something else is wrong. I asked the manager if they have worked on Priuses and he said no problem. They do everything. I then mentioned that they are unlike other cars and he said that they do them all the time. I don't think that they have encountered replacing a door. Somebody should have caught this. I've talked to the GM and he's a waste of time. I just find it strange that a women (me) who's not in the business has to tell them that the door isn't quite right. Whatever happened to comparing parts before replacing? There are other issued too. Wind noise that wasn't there before, the way the triangle window was cut out damaged the rubber around it, scratch on roof probably done by the magnetic number cone that they stick on the roof, light colored plastic at the base of the triangle window isn't seated properly. Keeps popping up. Plastic front window pillar is loose and probably not attached properly. I hate this!
     
  9. ZC1

    ZC1 Junior Prius Owner

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    Can you take these issues up with the insurance company, prior to getting the car back?
    These issues should not be happening if everyone else is doing their job, unfortunately, I see this as a sign of the times.

    Everytime I had mod work done on my Prius it was damaged somehow. It's getting to be that I have to do ALL the work myself and to almost shrink wrap the car before someone works on it.
    It's not being anal, but how would you feel if someone removes badly installed tint on your drivers door, so you get it removed by another tint shop, but the heat gun overheats the driver's side outer vertical black plastic trim which results in a palm sized shiny spot on an otherwise matte finish. I didn't notice it until a week or so later and didn't contest it since it would be difficult to prove. I'm just gonna buy another trim piece and install it MYSELF.

    I hope the insurance company will help you get these issues fixed. I really feel for you.

    ZC1
     
  10. dogfriend

    dogfriend Human - Animal Hybrid

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    I think the sealant is something that the body shop is supposed to apply before repainting the replacement door. The locations of the sealant are shown in the Body Repair manual (available at Toyota tech info). Here is the section related to sealant and undercoating:
     

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  11. cabillings

    cabillings New Member

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    Dogfriend - I'm anxious to see the body repair manual page you sent, but I can't open your pdf.
     
  12. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Hi Chris,

    Thanks for calling this to our attention. I suggest you print out dogfriend's file as it clearly shows that the door seams should be caulked, and bring that to the bodyshop, since you apparently have to teach them about this.

    I had no idea that those seams were caulked - I had assumed those seams were welded. So thanks again for enlightening us about this.

    The other problems are evidence of bad workmanship. Keep complaining until it is done right. Good luck getting your car restored back to original condition.
     
  13. cabillings

    cabillings New Member

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    Dogfriend - Thank you for the info. The pdf opened after I downloaded it onto my desktop. I have e-mailed it to the body shop manager and hope they can do it with a professional look.
     
  14. cabillings

    cabillings New Member

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