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I have a 21 HC 294rl (under warranty, and extended) that has this problem as well. Been sparring with Keystone and the dealer for over two months now. $2k estimate for new door, decals, etc. The whole right side of the door from top to bottom has now pulled out. LCI and Keystones official fix is remove screws, then use larger and longer screws beginning from middle hinge out. Screws go into styrofoam, like that's gonna work! Anyways we have attempted the "fix" and now taken new pictures and writeup to respond. Round two here we come....
If your out warranty you have a few options you could try if your door and frame haven't totally self destructed yet:
1. 3 in 1 Penetrating oil starting top to bottom and let gravity work for you. Then keep lube up with normal 3 in 1 lube. This does help.....some.
2. Look at your friction hinges on top and bottom with the door open. On the barrels, you will see some dimples. Carefully drill them out. This is the "friction" part of hinge. Put some black sealant back in for looks. Be careful with door in the wind now.
3. This is last resort. Make sure the door firmly in the frame on the hinge side. We used ratchet straps at top, center, and bottom hinges to pull the door into frame. Very carefully as to not bend the middle of door. Be sure that the panel is far enough in the frame. With that done, the hinge side can be drilled and black rivets installed. (Panel needs to be far enough in the frame so rivets dont pull out). You will still have to lube hinges or drill out the friction pin to avoid the same issue again.
Have done a lot of research and this is not a new problem. "Friction Hinges" have been causing this issue for alot of people, for a long time. Sadly the only true fix is a recall and not use these any longer. Even more sad, the only way anything will change is through a Class action suit.
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