Since doors are repeatedly used by vehicle owner, they have a great influence on his or her perception of vehicle quality. The door open overload is an abusive load requirement for customer usage. The doors must withstand loads which force the door open against its stop, leading to concern over the effects of permanent set to the functioning of the door system and the margins/ flushness. Traditionally, the CAE is utilized to objectively evaluate the deflections and permanent set at the door latch to evaluate door open overload requirement. In this study, the FEA methodology has been applied to expand the scope beyond traditional method to simulate door open overload condition. The change in the margin and flushness due to the permanent set are evaluated using nonlinear analysis (ABAQUS). The results show that the method helps designers to ensure the door meets the margin/flushness criteria for door open overload condition during early stage of the door design process.