We just got a new 2020 Tucson Ultimate a few weeks ago and I just found this! Bolt missing from lower hinge on passenger front door. You can see a broken TAP in the hole! A yellow arrow was pointing to it in the door jam but it never got fixed at the factory! We have less then 500km on this car that we got a few weeks ago. The door will have to come off to fix this and it may be easy to do without damaging my brand new car! I have asked the dealership to replace the car with another one. Would you let them repair it or demand a new car?

 

Having worked for a dealership , depending on the competence of the tech, that can be easily corrected and be over with.

If you are happy with everything else from your "new baby" this is a minor item and should not affect the performance or operation of your new vehicle.

If you saw some of the new vehicles that sit out on the parking area or field before sale it could surprise you. They are brought in cleaned up and made to look great and that is what you see. None of those things do that much damage , if any, and the vehicle is still brand new. My opinion, Give them the opportunity to correct the problem and establish a good relationship with that service dept. It can pay big dividends up the road.

 

It may or may not be easy to get that out of there. I also don't want the car sitting in a body shop with the door off for any length of time, there goes that new car smell. Also makes me wonder what else was missed on this car. I agree to give them a chance to correct the issue. I am hoping for a replacement door off another new car at least or a replacement car at best. Paint color may or may not match on a replacement door.

 

I seriously doubt that you will receive a replacement door because of a broken bolt. The door doesn't have to be removed to correct that problem, just someone with the experience to know what to do to correct the problem. Even if whoever was assigned to repair the problem , all they would do , if they had to, would be to mark the position of the hinge, support the door, remove the remaining bolt(s) move the hinge out of the way and remove the broken piece It could probably be done in less that an hour. AND no paint matching problem.

How did you find that problem anyway?

 

I was getting out of the car and pushed to door all the way open and saw the yellow arrow sticker in the door jam. The door will have to come off to make an attempt to get the tap out and test fit a new bolt before going back on the car imo.

 

Having removed MANY broken bolts and studs , this is not a big job.. I can understand your concern and would like to assure you if that is all that is wrong, with the proper tools and knowledge a good tech will be able to handle that problem much easier than a possible electrical problem that could tie up , even a new vehicle , for days.

The service dept may decide to do the job internally or may send it out to a machine shop who would definitely have the tools to handle it.
If the work done is not right or made worse,then you , I think, would have a good reason to want it done properly or whatever it takes..

 

It looks like a broken tap is stuck inside
However, the hinge pin seems to be able to be removed and replaced easily
The hinge pin is shot and usually just replaced
Then a bolt is screwed into the bottom which holds the hinge pin in place.

Some one messed up. Cross threaded the bolt and tried to re-tap.
Then the tap broke and the five o'clock whistle blew (probably weekend).
Put a marker on it and come back later to fix
Except someone forgot to fix it.

 

Update on this issue. IT"S FIXED!
The door was removed and a Walton broken tap removal tool and a diamond tipped drill bit did the trick at the body shop.
I am getting a free oil change and color touch up stick for the car and some gas money for the inconvenience. They are covering the cost of the tools used.
So glad I didn't go with there suggested repair to replace the door and paint the side of the car.