ah extra washers!! neither all 4 doors have any of these and all 4 doors make clicking noise some worse than the other, ive read some where to grind the door check valley down a bit so the friction is less and wont pop as much and the door will still stop in that position but you think if its designed this way it should work right.

marc

 

It's always nice to know I'm not the only one!

 

Thanks for all the good advice... No more "pop"!

Although, I thoroughly greased the door-check guts... Like suggested... The focus of the solution was the hinge.

I tried many iterations... The final is: 1) The pin/bolt must fit snug in the hinge-holes 2) If a bolt is used in place of the pin, as I did, where the arm rides on the bolt must be smooth/no-threads 3) A spacer(nylon) is needed between the arm and hinge.

Pictures:

 

Glad that worked out for you but I should have been more clear. I apologize for that. I believe there to have been 2 nylon washers in there. With the arm for the door check being in between the 2. To keep it more straight. Yours looks a little crooked. Does it matter? Not a clue. Thought I had a shot. Took me forever to find it.

 

Good observation! I agree... Does it matter... Who knows. Because the shortest "partially-threaded" bolt I could find was a 30mm... Some of the threads were still visible inside the hinge. To error on the side of caution... I covered all the threads with a single nylon-washer. Keep me honest!

 

Good idea about covering the threads. Did not catch that. The threads could kinda attach to something. Had that problem with the steering stabilizer in a '96 once. The bolt that is by the passenger wheel was threaded the whole way. Actually ground itself into the rubber bushing on the steering stabilizer and would not come out. That was fun for a few minutes.

 

Since someone is watching my every-move... More details. Rubber-membrane under the hinge to cover some rub-marks in the paint from the previous hinge. Button-head screws to secure the hinge... So the bolt-head for the pin-holes would slide past the head of the button-head... As a standard-bolt-head was too high. Rubber-cap for for aesthetic purposes.

 

This is news to me. None of the doors on my '00 have these spacers and none of them pop.

 

I did the driver's side first. It needed to be done. There were none. Door was perfectly fine after I installed the door check. Always thought my passenger side door was OK. Until I did the driver's side and saw how it was supposed to be. When I did the passenger side that is when I found 1 spacer. The one with the cut out in the picture above. Then I looked at my back doors and so them too. So my OCD got the better of me and I found something at the hardware store to use.