HELP!! I've got a '94, and the previous owner(s) seem to have hyper-extended the driver door to the point where the door didn't close correctly. Thinking it was the hinges, I bought and replaced them, but I wasn't in luck.
Upon closer inspection, it looks like the A-Pillar itself is tweaked. (I compared the driver side to the passenger side which closes just fine. Its dark now, but tomorrow I'll provide pictures of both sides to better explain.)
Anyone have ideas? Has anybody had this problem?
Any body guys that has any ideas?

Thanks,
Mike

 

This may or may not help you, but for what's it's worth, I'll share what I did on a C3, not sure if it's possible on a C4 (haven't had that part of the A-pillar exposed on one). Anyway, had the same problem, getting the inner opening of A-pillar exposed was quite involved, I had to remove the whole dash, the door the hinges etc. Here's what I came up with, I did some some rough measurements of the rectangle area on the outside (where the door hinges bolt on) and the inside of that same area(behind kick panel) I used 1/2 plywood as a template and cut out pieces for the inside and outside (the inside had to be 2 separate pieces) I then kept trimming the inside ones until I could get them inside the A-pillar stacked one on top of the other). I marked the hinge bolt holes and the hole for the wiring harness boot from the outside with a Sharpie. The idea is, to sandwich the A-pillar metal between 3/8" plate steel on both sides, using the bolt holes and harness hole to run bolts through from the inside and put the nuts and washers on the outside (grade 8!!!!!) by tightening the nuts you are

"clamping" the A-pillar metal between the steel and since the steel is thick enough and spreading the load on both sides, the A-pillar metal can only flatten back out to where it originally was! No hammer, no prying, no unwanted distortion. Hard to describe this, used the wood as templates because it's easy to alter and get "right", then you only have to do the steel once! Steel has to be thick so it doesn't flex, if the wood fits the steel will. Tighten all bolts evenly, then back them off and do it again, and again...after a few times it'll be done moving and hopefully it'll be no worse for the wear! Here's some pictures, the extra plate on the one side I used to bridge the seam of the 2 individual pieces for the inside, the other small piece was extra. This is like putting your A-pillar in huge vise! Good luck, worked perfect for me 👍