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Door panel fatigue

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Old Sep 11, 2006 | 09:39 AM
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rtrhd616
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Door panel fatigue

I have a 2001 Expedition with about 105,000 miles on it and I was cleaning the windshield when I noticed a circular crack in the drivers side door about 3 inches above the door mirror on the sloped portion of the door. Upon closer inspection the circular piece broke off and fell into the door. I pulled off the interior door panel and pulled out the broken piece. It looks like a large bead of composite? material was left on the backside of the door panel and over time the vibration of it caused it to crack through to the outside. Has any one else experienced this problem? I looked over the rest of the door and found another spot on the inside of the door just across from the mirror that may be working its way through as well.
 
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