I am getting a loud cracking noise from the door hinges on first my passenger, and now my driver side. I know what the problem is: that little plate that the spring assembly attatches to has partially broken loose from the main door body [a pretty poor design I think]. I've has the pass. side spot welded once, but eventually the weld broke. What can I do next?

 

Have it welded properly.

Mine was broken on the 850 when i bought it about 6 yrs ago. Took it to an indy volvo shop; they welded it; been good ever since.