The top door hinge on my 06 plate MAN TGA has sagged and it means I am having to really slam the door to get it to shut. I spoke to the garage about this when it went in for my 6 weekly and they tell me it’s a common problem with the MAN/ERF door hinges. The fitter also said replacing the hinge would not solve the problem but I can’t see why not. Just wondered if anyone on here has had a similar problem and how it was solved. Cheers
ive heard of that been a very common the doors are to heavy for the hinges taking the plastic trim off the bottom of the door that covers the steps helps
There is a modified hinge available, we fitted them to ours. Can’t remember if it was a dealer part or if we got them from Imex though.
Gogan:
There is a modified hinge available, we fitted them to ours. Can’t remember if it was a dealer part or if we got them from Imex though.
I take it that solved the problem then? I couldn’t really understand the fitter when he said a new hinge wouldn’t solve it. Any ideas how much it cost? Also who are imex?
we had this with ours, we had to remove the door and weld up behind the hinge and also fit a new hinge, i didnt do it the fitter did, i will ask him tomorrow and post what he said, also, sell the man asap and get a fh12 manuel box, way better truck and dealers…
Yes it solved the problem. I think the hinges were around the £100+VAT mark, this was a couple of years ago. As richmond says also check where the hinge mount is welded to the cab frame, as the spot welds break and the hinge sits slightly proud of where it should, meaning that there is still a slight gap even with a new hinge.
Imex are a good place to get MAN parts, there was a time when they were much cheaper than the dealers but these days my local dealer will match their prices without any hassle, and in some cases are actually cheaper for common service items. You can find them at http://www.imexpart.com.
richmond:
we had this with ours, we had to remove the door and weld up behind the hinge and also fit a new hinge, i didnt do it the fitter did, i will ask him tomorrow and post what he said, also, sell the man asap and get a fh12 manuel box, way better truck and dealers…
I’ve only had the MAN since November and as its a new venture on my own it will be staying until I’ve earnt enough to replace it! I actually love the truck, nice cab, comfy to drive etc, not so sure about the auto box in snowy farmyards though!
Gogan:
Yes it solved the problem. I think the hinges were around the £100+VAT mark, this was a couple of years ago. As richmond says also check where the hinge mount is welded to the cab frame, as the spot welds break and the hinge sits slightly proud of where it should, meaning that there is still a slight gap even with a new hinge.Imex are a good place to get MAN parts, there was a time when they were much cheaper than the dealers but these days my local dealer will match their prices without any hassle, and in some cases are actually cheaper for common service items. You can find them at http://www.imexpart.com.
Thanks for the link mate, looks like they’ll have everything you could ever need. The fitter did say about taking the door off and modifying it with a bit of welding. It’s just knowing where to go I suppose.
If you like your TGA then stick with it. We’ve had 5 altogether over the last few years - 4 of them have been fantastic and one was a total lemon. I know other hauliers who think they are a good truck for the money, whereas others who have had a couple of bad ones won’t touch them now.
If you look after it and keep on top of the maintenance then it will serve you well, and like you say they have a good sized cab and are very comfy to drive once you get used to the auto box. My only complaint would be the in-cab storage, which I find a bit disappointing for a cab of its size.
there is also Lawman Commercials at Merry Lees, Leicestershire for MAN spares, they are a specialist MAN breaker
sell it, buy a volvo soon as my two are paid for, thats what i am doing, the volvo package is way better, although i have a good freind, who reckons the exact oposite to me !but i know im right…
xfmatt:
Thanks for the link mate, looks like they’ll have everything you could ever need. The fitter did say about taking the door off and modifying it with a bit of welding. It’s just knowing where to go I suppose.
just watch the paint when you are welding, we tried to fix one of ours like this and the paint bubbled on the door
xfmatt:
The top door hinge on my 06 plate MAN TGA has sagged and it means I am having to really slam the door to get it to shut. I spoke to the garage about this when it went in for my 6 weekly and they tell me it’s a common problem with the MAN/ERF door hinges. The fitter also said replacing the hinge would not solve the problem but I can’t see why not. Just wondered if anyone on here has had a similar problem and how it was solved. Cheers
If there is no obvious wear and tear to the top hinge put a block in the bottom hinge and push the door shut (It wont shut with the block in place) this will force/stress the bottom hinge back to a normal position and the door should shut OK.
Had my TGA for 6 1/2 years now with over 1m KM on the clock I have had some problems but no worse than other more expensive makes and better than most.
Turn your ASR off in the snow and use the MANUAL function for changing gear and you should be OK.
The new hinge will come with a modified backing plate for inside the door. If the door is cracked, just weld the cracks. DO NOT weld the hinge to the door. We run about 80 mans ina hire fleet and it’s rare a week would go by without replacing a hinge. I’ve seen some rough repairs done for this job, make sure it’s done properly. The man are quite a good truck in my opinion. Troublesome ebs problems, normally wiring breaks going to valve over axle. Get your hinge fixed as soon as possible because slamming the door damages the lock, which is electric, and can cause central locking to start locking the truck on its own. Easy to get into if manual box but a butch if auto
Had exactly the same with my ECT.
1st open the door and from the inside remove panel between door and windscreen, lift the front grill and you will be able to see where the 2 panels have come apart.
2nd get someone to lift the door as much as possible till the gap disappears - drill - bolt together and jobs a good one.
The chap who did mine used to work for stillers and had done it many times.
Mines been done 6 months and ain’t budged.
On our TGA the bearing in the top hinge had gone letting the door drop but the part that welds to the door was fine so we just split the new hinge and bolted the part that was needed to the cab. Every now and again the screw holding the two parts together comes slack and needs to be tightened.
Hope this helps.
I had exactly the same problem, the fitter came out and said ‘It’s your door hinge mate, it needs a new lorry’ 
Thanks for all the help guys, taking the wagon into MAN next weekend to see what they think. It looks like the option of either a modified hinge or repair and strengthen the exisiting one. Whichever way it goes im hoping it doesnt cost too much.
easy to fix without new hinges. open the door, put a bar in the gap between the bottom hinge so when you close the door the bar is wedged between the 2 parts of the hinge. push the door slowly but firmly & check the gap. repeat as necicary untill door is re alligned. peice of cake to do & man actuly have a bar to do this exact procedure 
. total cost of repair £0 pounds
A few of my own experiences with MAN’s:
If you get any problems with MAN dealers, try using a non franchise (i.e. MAN Timbuktoo instead of Joe Bloggs MAN). You’ll find a world of difference in service unless your local franchise is one of the few good ones.
Factor in turbo changes around the 350,000km to 450,000km mark.
Whenever you tilt the cab give the cab lock sensors a wipe to clean off the grease. It causes them to fail and the light and alarm comes on the dash. Though they’re relatively cheap and easy to change.
Always try and lift your mid lift on slow/tight conering as steering isn’t linked, it follows so the tyres rubb out on the edges.
Make sure your anti freeze/coolant mix is in spec. as it helps with the EGR manifold. If your using alot of water get it (EGR manifold) checked as if it fails you’ll need a tow.
If your auto box locks up and/or the engine fails to start cos it’s locked in gear call a franchise dealer’s service dept. they talk you thru the emergency override (something like foot on brake and accelerator and hold ingnition on start - but it was a few years ago now).
When approaching a hill use the manual setting to hold down any gear changes.
When changing any window opening modules you’ll need to get someone with MANCATS to get the code off the old one to enable the new one to work correctly (they are left hand drive set up from factory which means you’ll be working backwards and upside down).
If you want to fit an invertor send me a PM as i know where there’s a heavy duty cable which is what MAN use for any factory fit accessories which need one. The back wall is 2.2m long and ideal for installing a shelf using flat angle brackets tucked inside the panelling overlaps once the top bunk is removed (takes about 15 mins and a bit of a sweat).
it happened 2 years a go on mine but the door fell off in the driver hand!!! needed 2new hinges… been ok since!!!