Just to be clear, when you say tweaking the bottom hinge, do you mean the rubber mallet between door and frame, or actually trying to adjust the hinge ?. Also I have been thinking if I want to get the bottom of the door in,then maybe I should try and bend the top of door out ?.

Suffolkman you are right, I thought you were talking more about the gap which is 2 plane up and down. Not sure the Ford shop manual process will help with what you have. Sounds like your door is warped probably due to a past wreck with either a warped door or a cab problem. Good luck with it.

Every F1 I've come across has this problem, the pass. door shuts tight while the driver door hangs out an eighth to a quarter inch. I think it has to do with all the flex in the stock frames, you just don't realize how much the frame twists up on the right side especially with a more powerful engine. Look at the margins where the lower fenders meet the rails just behind the bumpers, most of the f1s' I've looked at have different gaps from one side to the other, all this due to frame flex. This in my humble opinion of course.

My observations are the same. I just get it as close as possible and then leave it.