Rear Door: Service and Repair
Door Outer Panel
Door Assembly - Exploded View
NOTE: Front door shown, rear door similar. Door intrusion beam is constructed of Boron steel and is non-serviceable.
WARNING:
- Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or damaged vehicles. The use of such parts could lead to serious injury.
- Never use non-Ford parts or accessories for completing repairs.
Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain damage which is not visible.
- Ford does not approve use of the following:
- Salvaged or used parts
- Major body clips or assemblies from salvage vehicles
- Aftermarket structural or body components
- Salvaged or reconditioned wheels
- Used supplemental restraint system (SRS) components
- air bags
- restraint system modules
- safety belts, buckles or retractors
- crash sensors
- Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company engineers.
- Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and corrosion protection.
- Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative structural component repair procedures and/or parts.
- Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.
- Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.
1. NOTE: Inspect the door hinges prior to panel replacement. Repair or rebuild as necessary.
Remove the window glass from the affected door.
2. Remove the door assembly and secure on a workstand.
3. Remove the mirror assembly.
4. Remove the outside door handle.
5. Remove door trim including mouldings and weatherstrips.
6. NOTICE: Do not cut through inner door panel or belt line reinforcement or damage to the door assembly and potential corrosion points may result.
Using a spot weld cutter or equivalent, locate and drill out the spot welds on the door panel.
7. NOTICE: Use extreme care to avoid cutting the door shell or inner panel or the door assembly may be damaged.
Using a grinder, grind along the perimeter of the outer door panel hem to separate the hem edges as indicated in the illustration.
8. NOTE: The use of a Heat Gun may be required to soften door panel adhesive.
Prior to removing the outer panel, use a sharp knife to cut the adhesive between the door outer panel, flutter beam, beltline reinforcement and intrusion beam.
- Using a flat-blade chisel or equivalent, remove the original panel.
- Using a sharp knife or broad edge scraper, remove the remaining portion of the hem flange from the door shell.
- Remove any remaining adhesive from the door shell flange.
9. Prepare the door shell assembly.
- Grind clean all the mating surfaces of the inner hem
- Dress any spot weld nuggets
10. NOTE: Spot welds may be replaced with Metal Inert Gas (MIG) plug welds. Plug welds should equal spot welds in both location and quantity. Plug welds should be staggered to avoid placement directly over old spot weld. Plug weld hole should equal 8 mm (0.31 in) diameter.
Prepare the service replacement panel.
- Grind clean all the mating surfaces of the replacement panel.
- If MIG welding, drill plug weld holes in the window opening area.
- Apply a mastic sound-deadener patch (obtain locally), to the inner side of the replacement panel.
11. NOTE: Refer to adhesive manufacturer's label instructions and cure times. Hemming and alignment must be completed before the adhesive has begun to cure.
Apply metal bonding adhesive to the replacement panel hem flange and position on the door shell and begin the hemming process.
- Using a door panel installation tool or the hammer and dolly method, close the door hem flange around the entire perimeter of the door and smooth any residual adhesive in the joints.
12. Temporarily fit the assembly to the vehicle and assure correct alignment with the adjoining panels.
- Clamp the window opening flange and apply 3 or 4 MIG plug welds or resistance spot welds to secure the panel in place.
13. Remove the door and complete the welding process.
14. Working from inside the door, apply flexible foam to the following areas: intrusion beam-to-outer panel, flutter beam-to-outer panel and outer belt reinforcement-to-outer panel.
15. Sand and prime the flange area and apply a continuous bead of seam sealer to the entire door hem flange perimeter.
16. Install the door on the vehicle.
- Refinish using a Ford-approved paint system.
17. Apply rust inhibitor inside the door to all hem areas and upper beltline area. For additional information, refer to Restoring Corrosion Protection Following Repair.
18. Install the outer door handle.
19. Install the window glass.
20. Install the side view mirror.
21. Install the exterior trim.