Just so busy....! I finally took the door off, took off the bottom hinge which had two of four bolts snapped. Drilled those out and tapped holes. I noted that another shim or two were needed to align the door better before I took it off. Some sheet metal and snips took care of that. I went ahead and sprayed converter primer and some paint for good measure. Once the hinge was back on I had to do a combo of adjusting and I did use another shim behind the bottom body hinge plate.
Another issue that might have contributed to the problem was the phillips screws that fasten the latch mech to the edge of the door were bending/elongating through their holes in the door sheet metal. I used a bolt washers and nut to press them back. Easy and it really reformed them so all 4- screws are engaged.The jamb strike needed adjusting so as to make the first notch and the second notch work with the star shaped latch. Hard to explain but not to complex once you dig in.
It closes. Sounds dumb but these little things add up and dinking around with retapping holes and stuff made a simple door adjustment take 2 hours. Reality man
Other tidbits would be the plastic dust wrap around the inside access panels, the outside lock connection that often falls off, one biggie was my pass. is okay and unmauled but the driver star thing is worn and is not an issue now but could be soon....I see that the star tips can be added to with a welder (BTW, so can the window reg gearing when worn) and filed to shape, also the underside of the strike on the jamb side gets grooved and could be filled with weld. BTW, the black metal "H" in the name the part game is the back plate to the hinge and the 5/16 hole was stripped so I weld filled and retapped.
