[73mach1429]

The problem is that the spot welds that hold the door checker plate to the door, fail. If caught early, i.e. when the "popping noise" starts, the door can be welded. If you wait to long, the door checker plate becomes cracked and/or broken and door replacement is required. I have performed this repair a few times and when I repair these, I install extra welds in 2-3 more locations to make it stronger than a new door. The repair consists of drilling out the old spot welds, repositioning the checker plate, welding it back in place and touching up the paint over the welds. If done properly, the repair is barely visible in the area of the checker.