(This was done on drivers door, should be similar on passenger) Ok, so I searched for how to repair this on the forum, I think I searched pretty thoroughly, and all I could find was a pretty neat velcro fix, but I wanted more. So, hopefully this can help someone! It took a fair amount of thinking and trial and error before we figured it out, especially figuring out how the little springs in there worked! So, now I can tell you! Just so you know, I read that some people lost the springs, this repair did require having both springs. My buddy and I removed the door panel, replaced the ML speaker, and went to work on my drivers door expandable door pocket. Hopefully these pictures help, because I'm not sure if my verbal direction will be totally sufficient, I will do my best though. One side of my expandable door pocket was still functioning, the other was causing it to fall open.

Step one: Remove door panel.

Step two: behind the insulation carpet, on the back of the door panel (you can pull the carpet without fully removing it), so behind the insulation carpet you will find 5 screws, 3 on one side, 2 on the other, to remove the panels that the expandable door slides on.

Step three: DON'T lose the springs!

Step four: near the bottom of the door panel side holders, you will find a plastic nub that is the lowest pivot point of the door (both of mine were broken). In order to continue the repair, we drilled and then set two screws to hold the door in the pivot position. This allows you to begin the work on reattaching the springs. See below picture:

Lowest Pivot Point Screw (We did this on both sides):



Step 5: Once we attached the holder panels to the expandable door itself, using our new pivot screws. On one side we drilled a hole to hold the spring where the plastic clip, meant to hold the spring, had broken off (this was causing the problem), and inserted the spring. (This may last longer than the clip on the other side and I was tempted to do both but didn't as one side still had the clip). Then put the springs in their homes. See below pictures:

Closed and open pictures of modification to accommodate the missing plastic clip which holds the spring:


Closed with hole drilled to hold the spring, in absence of the clip due to it being broken off.

Open with hole drilled to hold the spring, in absence of the clip due to it being broken off.

Next, I will attach pictures that show how the other side, which still had the plastic clip, to hold the spring, in place:

Closed and open pictures of modification to accommodate the missing plastic clip which holds the spring:





Step 6: Put the door, with side panels attached, and springs in place, back in the actual door panel, put 5 screws back in attaching door and panels back to main door panel, put the door panel back on, and ENJOY!

In all of these pics you can see at the bottom our lowest pivot point modification as well.

Hope this helps someone!!

Thanks, Nate!

P.S.

HAPPY 4/30 DAY!!!!!

 

Looking good. I did the hinge screw trick on the driver side of my LS, but only had 1 spring left and everything else was missing so I found a couple convenient places to use (2) self-drilling screws per side. The driver pocket is now 100% fixed in place, which is an option if you're missing springs and parts like I am.

 

Pretty much exactly what I did to my Pax side on the 2001 last year. Great write up and a solid repair.