How to Replace a Storefront Flush Bolt on Double Doors

Hey guys, this is Gary with Door Closers USA. In today’s video, we’re going to show youhow to remove a flush bolt and replace it on a commercial storefront double door system.

Flush bolts are commonly found on double door storefront openings. Most setups use two flush bolts:

• Bottom flush bolt: Drops down into the threshold
• Top flush bolt: Slides up into the head / frame pocket

These bolts secure the inactive door, and over time the internal nylon guide and wear surfaces canbreak down and require replacement.

How Storefront Flush Bolts Work

Flush bolts lock the inactive door in place. When you flip the lever:

• The lower bolt plunges down into the threshold
• The upper bolt plunges up into the head area

The rod is kept aligned by a nylon guide. Over years of use, that guide can wear out, causing pooroperation or failure to latch properly.

Common Signs a Flush Bolt Needs Replacement

• Rod won’t engage into the hole (top or bottom)
• Lever feels sloppy or doesn’t hold position
• Nylon guide is cracked, worn, or broken
• Rod is bent or damaged

You may also notice grease or residue on newer flush bolts. This is often normal and can usually bewiped clean. The real problems are typically obvious—damage to the rod, guide, or latch action.

Removing the Flush Bolt (Top Bolt Example)

In this video, we’re replacing (or demonstrating removal of) the upper flush bolt.

Step 1: Prop the Door Open

Use a floor stop or door wedge to hold the inactive door open so you have room to work.

Step 2: Remove the Nylon Guide First

Remove the screws holding the nylon guide in place.When removing the guide, hold it so it doesn’t drop into the door stile.

Once removed, you’ll see how the guide keeps the rod aligned as it moves up and down.

Step 3: Remove the Flush Bolt Body

Next, remove the screws securing the flush bolt body. As you do this, hold the rod so it does not dropdown inside the door.

For the top bolt, you can typically slide the assembly up and out through the top opening once thehardware is removed.

Adjustment Tip: Match the Original Rod Height

When installing a new flush bolt, it’s important to set it up to match the original adjustment.Flush bolt rods are typically threaded with a lock nut, which allows height adjustment.

Before installing a new unit, make sure:

• The rod is threaded in approximately the same amount as the original
• The lever action aligns with the existing holes in the frame / threshold

This helps ensure the bolt engages smoothly without needing trial-and-error adjustments.

How to Identify the Correct Replacement Flush Bolt

The easiest way to get the correct replacement is to identify your door make and model.Storefront doors often have branding on the bottom rail.

If you don’t know the make/model, you can call in and we can walk you through how to measure and matchthe correct flush bolt.

We carry flush bolts for all makes and models at DoorClosersUSA.com.

Reinstalling the Flush Bolt and Guide

To reinstall:

1. Set the flush bolt back into the mortised pocket
2. Start the screws so the bolt is held in place
3. Reinstall the nylon guide and tighten securely

Once installed, test the bolt action by flipping it up and down and confirming it engages properly.

Bottom Flush Bolt Note

If you’re replacing the bottom flush bolt, it may be possible to route the rod through the access hole,depending on the door. Another option is to remove the door and lay it on sawhorses for extra room.

Bottom bolts can take a bit more “fine tuning” to line up with the threshold hole, but once aligned,they should engage smoothly.

Final Notes

That’s how you remove and replace a flush bolt lock on a storefront double door system.All flush bolts and replacement parts are available at DoorClosersUSA.com.

If you have questions, call us, email us, or send photos of your hardware and we’ll help you identifythe correct replacement.

Thanks for watching.

Watch the Video

Prefer to follow along visually? Watch the full video below to see the flush bolt removal andreplacement process step-by-step.