I've seen this happen when a wreck (hit on one side in front) deforms the cab just enough so the door won't work anymore. Fixing it ain't always fun.

If you try to spread the hinge pillar and the latch pillar with 2 x 4s and a jack, you can do this, but honestly speaking the risk of failure gets exponentially higher the more you need to move things. Having to move these apart by 1/8" is a lot more than it might sound like, but it can be done. Before you try this, please remove the windshield. The first thing to start moving (every single time) will be the pillar that connects your cowl to your roof--and that forms the plane for your windshield. The pinchweld must remain correctly aligned and on the same plane, or you'll have trouble and it will flex right where it connects to the roof. Even if you don't break the weld connecting the pillar to the roof, I've seen people crack windshields just by moving/flexing the pillar. You can use a very flat piece of plywood cut to match the good windshield opening to know when the size/angle is right and then reinstall the windshield. Sorry...I don't know of an easier way to fix this. Even if you have access to very sophisticated straightening equipment, you still have to remove the windshield to straighten this area.

Good luck!


~ Jon
1952 1/2 ton with 1959 235 | T5 with 3.07 rear end